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FDF03 Food Processing IndustryTraining Package

Volume 2 of 5

Version Number: 3Review Date: 30 April 2006

FDF03Food Processing Industry Training Package

The Food Processing Industry Training Package (FDF03) is comprised of five volumes, threefor the food processing sector, and two for the wine sector.

Volume 2 of 5Food Processing Sector

This Training Package was endorsed by NTQC in March 2003.

This Training Package is to be reviewed by April 2006

FDF03 Food Processing Industry Training Package (Version 3) Date this PDF was generated: 08 November 2007Title Page

Volume 2 of 5 Page 1 of 760© Commonwealth of Australia, 2007 To be reviewed by: 30 April 2006

FDF03 - Food Processing Industry Training Package

© Commonwealth of Australia, 2007

This work has been produced with the assistance of funding provided by the CommonwealthGovernment through the Department of Education, Science and Training (DEST).

An individual may make a photocopy of all or part of the work for their personal use.

A Registered Training Organisation may make photocopies of all or part of the work for theteaching purposes of that organisation, including for supply to its students provided that anyconsideration does not exceed the marginal cost of preparation, reproduction, assembly anddelivery.

Except as permitted under the Copyright Act 1968, all other rights are reserved. Requests forpermission may be directed to:

Branch Manager,

Technology and Information Services Branch,

Industry Skills Development Group,

Department of Education, Science and Training,

GPO Box 9880 Canberra City, ACT, 2601.

Website: www.dest.gov.au

This work is the result of wide consultations with Australian industry participants. It is acollaborative view and does not necessarily represent the view of DEST or any specific body.For the sake of brevity it may omit factors which could be pertinent in particular cases.

While care has been taken in the preparation of this Training Package, DEST and the originaldeveloper do not warrant that any licensing or registration requirements specified here areeither complete or up-to-date for your State or Territory. DEST and the original developer donot accept any liability for any damage or loss (including indirect and consequential loss)incurred by any person as a result of relying on the information contained in this TrainingPackage.

This Training Package should not be regarded as professional advice and it should not berelied upon in any important matter without obtaining appropriate advice relevant to yourcircumstances.

Published by:

First published: 9 June 2003

ISBN: 0 642 79960 1

Printed by:

AEShareNet Code: FfE

Print Version No: 3

Release Date: August 2007

FDF03 Food Processing Industry Training Package (Version 3) Date this PDF was generated: 08 November 2007Imprint Page


http://www.dest.gov.au

TABLE OF CONTENTS

Version Modification History............................................................................................................................... 6

Qualifications Framework.................................................................................................................................... 9

The Australian Qualifications Framework............................................................................................................9Skill Sets............................................................................................................................................................19

Assessment Guidelines......................................................................................................................................21

Introduction........................................................................................................................................................21Assessment System Overview..........................................................................................................................21Australian Quality Training Framework Assessment Requirements................................................................. 21Licensing/registration requirements.................................................................................................................. 22Pathways...........................................................................................................................................................23

Designing Assessment Tools............................................................................................................................ 26

Use of Assessment Tools..................................................................................................................................26Using Prepared Assessment Tools................................................................................................................... 26Developing Assessment Tools.......................................................................................................................... 26Conducting Assessment....................................................................................................................................26Access and Equity.............................................................................................................................................27

Assessment in the Food Processing Industry................................................................................................. 27

Futher Sources of Information...........................................................................................................................28General Resources........................................................................................................................................... 29Assessment Resources.....................................................................................................................................30Assessment Tool Design and Conducting Assessment....................................................................................30Assessor Training..............................................................................................................................................30Assessment System Design and Management.................................................................................................31

Units

FDFAWDMC2A Operate a deaeration, mixing and carbonation process......................................................... 32FDFBISETP2A Manufacture extruded and toasted products............................................................................39FDFBISFS2A Operate a forming/shaping process........................................................................................... 45FDFBISRC2A Manufacture rye crisp breads.................................................................................................... 51FDFBISWP2A Manufacture wafer products......................................................................................................57FDFCAKCSP2A Operate a cooling and slicing process................................................................................... 63FDFTCRG2B Manufacture coffee (roast and ground)...................................................................................... 68FDFCONFBS2A Operate a boiled confectionery process................................................................................ 74FDFCONFCC2A Operate a chocolate conching process................................................................................. 81FDFCONFCP2A Operate a chocolate depositing/moulding process................................................................86FDFCONFDP2A Operate a confectionery depositing process......................................................................... 92FDFCONFGC2A Operate a granulation and compression process..................................................................98FDFCONFPP2A Operate a panning process..................................................................................................104FDFCONFRC2A Operate a chocolate refining process..................................................................................110FDFCONFSM2A Operate a starch moulding process.................................................................................... 116FDFDPBC2B Operate a butter churning process........................................................................................... 122FDFDPBF2B Operate a continuous freezing process.....................................................................................127FDFDPBOP2A Operate a butter oil process................................................................................................... 132FDFDPCC2B Operate a curd production and cutting process........................................................................138FDFDPCH2B Operate a cooling and hardening process................................................................................143FDFDPCM2B Operate a cheese pressing and moulding process.................................................................. 148FDFDPFP2B Operate a fermentation process................................................................................................153FDFDPHS2B Operate a holding and storage process....................................................................................158FDFDPMP2B Operate a membrane process..................................................................................................163FDFEOBP2B Operate a bleaching process.................................................................................................... 169FDFEOCP2A Operate a complecting process................................................................................................ 174FDFEODP2B Operate a deodorising process.................................................................................................180FDFEOFL2A Operate a flake preparation process......................................................................................... 185FDFEOFP2B Operate a fractionation process................................................................................................ 191FDFEOHP2B Operate a hydrogenation process............................................................................................ 196FDFEOIN2B Operate an interesterification (IE) process.................................................................................201FDFEONP2B Operate a neutralisation process..............................................................................................206

FDF03 Food Processing Industry Training Package (Version 3) Date this PDF was generated: 08 November 2007Table of Contents


FDFEOSSP2A Operate a soap splitting process............................................................................................ 211FDFEOWP2B Operate a winterisation process.............................................................................................. 216FDFFMCO2B Operate a grain conditioning process.......................................................................................221FDFFMGC2B Operate a grain cleaning process............................................................................................ 226FDFFMPP2B Operate a purification process.................................................................................................. 231FDFFMSG2B Operate a scalping and grading process..................................................................................236FDFFMSS2B Operate a scratch and sizing process.......................................................................................241FDFFMWB2B Operate a break roll process....................................................................................................246FDFFVFP2B Operate a freezing process....................................................................................................... 251FDFHYCH2A Operate a creamed honey manufacture process..................................................................... 256FDFICIM2A Operate an ice manufacturing process....................................................................................... 262FDFIMEPC4A Establish process capability.................................................................................................... 267FDFIMMIA4A Manage Internal Audits.............................................................................................................270FDFIMMWB4A Manage a work area within budget........................................................................................ 277FDFFSACA Assess compliance with food safety programs........................................................................... 281FDFFSBM4A Audit bivalve mollusc growing and harvesting processes.........................................................289FDFFSCC4A Audit a cook chill process..........................................................................................................296FDFFSCFSAA Conduct food safety audits..................................................................................................... 304FDFFSCHZA Identify, evaluate and control food safety hazards....................................................................315FDFFSCOMA Communicate and negotiate to conduct food safety audits..................................................... 322FDFFSHT4A Audit a heat treatment process..................................................................................................327FDFFSME4A Audit manufacturing of ready-to-eat meat products..................................................................336FDFOPTAP3A Participate in an audit process................................................................................................346FDFPHCCP4A Participate in change control procedures............................................................................... 351FDFPHCON2A Operate a concentration process...........................................................................................356FDFPHEXT2A Operate an extraction process................................................................................................360FDFPHFCC4A Facilitate contamination control.............................................................................................. 364FDFPHFIL2A Operate a filtration process using diatomaceous earth............................................................ 369FDFPHGMP4A Facilitate and monitor Good Manufacturing Practice.............................................................373FDFPHRNC4A Respond to non-conformance................................................................................................378FDFPHRWD4A Prepare and review workplace documentation to support GMP........................................... 382FDFPHSPC2A Operate a separation process using chromatography............................................................388FDFPHVP4A Participate in validation processes............................................................................................392FDFPASFF2A Operate a pastry forming and filling process...........................................................................398FDFPASMD2A Operate a doughnut making process..................................................................................... 404FDFPASMG2A Operate a griddle production process....................................................................................411FDFPASMP2A Operate a pastry production process..................................................................................... 416FDFPMMAC5A Manage supplier agreements and contracts......................................................................... 422FDFPMMPW4A Manage people in the work area.......................................................................................... 425FDFPMOHS4A Manage the implementation of occupational health and safety policies and procedures in theworkplace........................................................................................................................................................ 429FDFPHAFS2A Operate an aseptic fill and seal process................................................................................. 439FDFPHCLS2A Co-ordinate a label store.........................................................................................................446FDFPHCP2B Operate a compressing process............................................................................................... 449FDFPHDRM2A Dispense pharmaceutical raw materials................................................................................ 454FDFPHEP2B Operate an encapsulation process........................................................................................... 459FDFPHFFS2A Operate an aseptic form, fill and seal process........................................................................ 464FDFPHGP2B Operate a granulation process................................................................................................. 471FDFPHLM2B Operate a liquid manufacturing process................................................................................... 476FDFPHTC2B Operate a tablet coating process.............................................................................................. 482FDFPHTSP2A Operate a terminal sterilisation process..................................................................................488FDFPLDMP5A Design and maintain programs to support legal compliance..................................................493FDFPLPCM4A Plan and co-ordinate maintenance.........................................................................................498FDFPLSCP4A Schedule and manage production.......................................................................................... 504FDFPBBDM3A Operate a dough mixing process........................................................................................... 509FDFPBBFP3A Operate a final proof and baking process............................................................................... 516FDFPBBMU3A Operate a dough make up process........................................................................................523FDFPBSW2B Operate a cooling, slicing and wrapping process.....................................................................529FDFPBW1A Participate effectively in a workplace environment (plant baking).............................................. 534FDFPOAC2A Operate an automated cutting process.....................................................................................537FDFPOCWS3A Operate a chickway system.................................................................................................. 542FDFPODF3B Debone and fillet product (manually)........................................................................................ 547FDFPODM2B Operate a dicing/stripping or mincing process......................................................................... 552FDFPOEP2B Operate an evisceration process.............................................................................................. 557FDFPOGC2B Grade carcass.......................................................................................................................... 563FDFPOHE2A Harvest edible offal................................................................................................................... 567



FDFPOOIM2A Operate a marinade injecting process.................................................................................... 572FDFPOOWC2A Operate a washing and chilling process............................................................................... 577FDFPOPS2A Operate a portion saw...............................................................................................................583FDFPORH2A Operate the bird receival and hanging process........................................................................587FDFPOSK2B Operate a stunning, killing and defeathering process...............................................................592FDFPIOWP4A Optimise a work process.........................................................................................................597FDFRBAB3A Produce artisan breads............................................................................................................. 602FDFRBBB2B Bake bread................................................................................................................................607FDFRBBC2B Bake sponges, cakes and cookies............................................................................................610FDFRBBP2B Bake pastry products................................................................................................................ 613FDFRBCP2B Produce choux pastry............................................................................................................... 616FDFRBDC2B Decorate cakes and cookies.....................................................................................................621FDFRBDPB3A Diagnose and respond to product and process faults (bread)................................................626FDFRBDPC3A Diagnose and respond to product and process faults (pastry, cake and cookies)................. 630FDFRBFD2B Freeze dough............................................................................................................................ 634FDFRBFF2B Form and fill pastry products..................................................................................................... 638FDFRBFM2B Conduct final mould and final proof.......................................................................................... 643FDFRBFP1B Finish products.......................................................................................................................... 647FDFRBGT3A Produce and decorate gateaux and tortes................................................................................651FDFRBPC2B Produce sponge, cake and cookie batter..................................................................................656FDFRBPD2B Produce bread dough............................................................................................................... 661FDFRBPD3B Participate in product development...........................................................................................665FDFRBPF2B Prepare fillings...........................................................................................................................667FDFRBPM2B Produce meringue-based products.......................................................................................... 672FDFRBPP2B Produce pastry.......................................................................................................................... 677FDFRBPY2B Produce yeast-raised products................................................................................................. 682FDFRBRD2B Retard dough............................................................................................................................ 687FDFRBSM2B Scale and mould dough for intermediate proof.........................................................................690FDFRBSP3B Plan and schedule production...................................................................................................693FDFSFGP2B Operate a grinding process.......................................................................................................696FDFSFPFP2A Operate a pelleting process.................................................................................................... 701FDFTECCCS4A Control food contamination and spoilage.............................................................................706FDFTECENG4A Apply basic engineering principles to a food production process........................................ 711FDFTECENV4A Manage the implementation of environmental management policies and procedures in theworkplace........................................................................................................................................................ 717FDFTECFAD4A Apply an understanding of food additives.............................................................................725FDFTECLEG4A Apply an understanding of legal requirements in food production........................................728FDFTECNUM4A Describe and analyse data using mathematical principles..................................................731FDFTECPAK4A Apply principles of food packaging....................................................................................... 734FDFTECPPR4A Participate in product recalls................................................................................................ 739FDFTECPSC4A Identify the physical and chemical properties of materials, food and related products........ 742FDFTECPT5A Manage and evaluate new product trials................................................................................ 747FDFTECUTE5A Manage utilities and energy for a production process.......................................................... 752FDFTECWTP4A Manage water treatment processes.................................................................................... 756



Version Modification HistoryThe version details of this endorsed Training Package are in the table below. The latest information isat the top of the table.

Version Release Date Comments

3 August 2007 Addition of imported TAA units to replace former BSZ units inthe Wine Sector qualifications.

• TAADEL301A Provide training through instruction anddemonstration of skills

• TAAASS401A Plan and organise assessment• TAAASS402A Assess competence• TAAASS404A Participate in assessment validation.

Addition of two qualifications in pharmaceutical manufacturing.(Refer Qualifications Framework pages 34 and 35):

• FDF40207 Certificate IV in Pharmaceutical Manufacturing• FDF50207 Diploma of Pharmaceutical Manufacturing.

Addition of two qualifications in food safety auditing (referQualifications Framework pages 42 and 43):

• FDF41007 Certificate IV in Food Processing (Food SafetyAuditing)

• FDF51007 Diploma of Food Processing (Food SafetyAuditing).

Assessment Guidelines and Qualifications Framework textupdated to conform to new requirements.

Historic information (former Table 18 and Table 19) precedingthis version of the FDF03 can be found atwww.agrifoodskills.net.au

Information to assist with implementation of the FDF03 TrainingPackage has been placed in the Appendices of Volume I:

• Appendix One Listing of all units grouped by AQF levelwithin sector or functional group (This informationreplaces the former Table 18.)

• Appendix Two Competency profiles.

Addition of four high risk food safety auditing Specialist units toAQF 4 and 5:

• FDFFSBM4A Audit bivalve mollusc growing andharvesting processes

• FDFFSME4A Audit manufacturing of ready-to-eat meatproducts

• FDFFSHT4A Audit a heat treatment process• FDFFSCC4A Audit a cook chill process

New FDF units added to pharmaceutical manufacturingqualifications:

• FDFPHCCP4A Participate in change control procedures

FDF03 Food Processing Industry Training Package (Version 3) Date this PDF was generated: 08 November 2007Version Modification History


http://www.agrifoodskills.net.au


• FDFPHFCC4A Facilitate contamination control• FDFPHGMP4A Facilitate and monitor Good

Manufacturing Practice• FDFPHRNC4A Respond to non-conformance• FDFPHRWD4A Prepare and review workplace

documentation to support GMP• FDFPHVP4A Participate in validation processes

Addition of four pharmaceutical specialist units to the CertificateII in Pharmaceutical Manufacturing:

• FDFPHEXT2A Operate an extraction process• FDFPHCON2A Operate a concentration process• FDFPHFIL2A Operate a filtration process using

diatamatious earth• FDFPHSPC2A Operate a separation process using

chromatography

Revision and recoding of pharmaceutical core units (GMP) atAQF 2 and 3:

• FDFPHMGMP2A Apply Good Manufacturing Practiceprocedures

• FDFPHMGMP3A Monitor and maintain GoodManufacturing Practice procedures

Revision of food safety auditing units:

• FDFIMMA4A Manage internal audits• FDFOPTAP3A Participate in an audit process

Addition of imported units at AQF 4 and 5 to replace formerBSZ units.

• TAADEL301A Provide training through instruction anddemonstration of skills

• TAAASS301A Contribute to assessment• TAAASS401A Plan and organise assessment• TAAASS402A Assess competence• TAAASS403A Develop assessment tools• TAAASS404A participate in assessment validation• TAADES402A Design and develop learning programs

2 April 2005 Four new Food Safety Auditing units have been added to theFood Processing Training Package.

1 June 2004 Category 1 maintenance to Wine Sector only, including codeand title updates and corrections of typographical errors.Includes amendments required to units imported from FDF03Food Processing Industry Training Package - Food Processingsector, due to changes made to those units during the periodthe Wine Sector Training Package was undergoingendorsement.




1.00 June 2003 First release

Forms control: All endorsed training packages will have a version number displayed on theimprint page of every volume constituting that training package. Every training package willdisplay an up-to-date copy of this modification history form, to be placed immediately after thecontents page of the first volume of the training package. Comments on changes will onlyshow sufficient detail to enable a user to identify the nature and location of the change.Changes to training packages will generally be batched at quarterly intervals. Thismodification history form will be included within any displayed sample of that training packageand will constitute all detail available to identify changes.



Qualifications Framework

The Australian Qualifications Framework

What is the Australian Qualifications Framework?

A brief overview of the Australian Qualifications Framework (AQF) follows. For a fullexplanation of the AQF see the AQF Implementation Handbook, 3rd Edition 2002. You candownload it from the Australian Qualifications Advisory Board (AQFAB) website (www.aqf.edu.au) or obtain a hard copy by contacting AQFAB on phone 03 9639 1606 or byemailing AQFAB on [email protected]

The AQF provides a comprehensive, nationally consistent framework for all qualifications inpost-compulsory education and training in Australia. In the vocational education and training(VET) sector it assists national consistency for all trainees, learners, employers and providersby enabling national recognition of qualifications and Statements of Attainment.

Training Package qualifications in the VET sector must comply with the titles and guidelines ofthe AQF. Endorsed Training Packages provide a unique title for each AQF qualification whichmust always be reproduced accurately.

Qualifications

Training Packages can incorporate the following eight AQF qualifications.

• Certificate I in ...• Certificate II in ...• Certificate III in ...• Certificate IV in ...• Diploma of ...• Advanced Diploma of ...• Vocational Graduate Certificate of ...• Vocational Graduate Diploma of ...

On completion of the requirements defined in the Training Package, a Registered TrainingOrganisation (RTO) may issue a nationally recognised AQF qualification. Issuance of AQFqualifications must comply with the advice provided in the AQF Implementation Handbookand the Australian Quality Training Framework Standards for Registered TrainingOrganisations, particularly Standard 10.

Statement of Attainment

Where an AQF qualification is partially achieved through the achievement of one or moreendorsed units of competency, an RTO may issue a Statement of Attainment. Issuance ofStatements of Attainment must comply with the advice provided in the AQF ImplementationHandbook and the Australian Quality Training Framework Standards for Registered TrainingOrganisations, particularly Standard 10.

Under the Standards for Registered Training Organisations, RTOs must recognise theachievement of competencies as recorded on a qualification or Statement of Attainmentissued by other RTOs. Given this, recognised competencies can progressively build towardsa full AQF qualification.

AQF Guidelines and Learning Outcomes

The AQF Implementation Handbook provides a comprehensive guideline for each AQFqualification. A summary of the learning outcome characteristics and their distinguishingfeatures for each VET related AQF qualification is provided below.

FDF03 Food Processing Industry Training Package (Version 3) Date this PDF was generated: 08 November 2007Qualifications Framework


http://www.aqf.edu.au

Certificate I

Characteristics of Learning Outcomes

Breadth, depth and complexity of knowledge and skills would prepare a person to perform adefined range of activities most of which may be routine and predictable.

Applications may include a variety of employment related skills including preparatory accessand participation skills, broad-based induction skills and/or specific workplace skills. Theymay also include participation in a team or work group.

Distinguishing Features of Learning Outcomes

Do the competencies enable an individual with this qualification to:

• demonstrate knowledge by recall in a narrow range of areas;• demonstrate basic practical skills, such as the use of relevant tools;• perform a sequence of routine tasks given clear direction• receive and pass on messages/information.

Certificate II


Breadth, depth and complexity of knowledge and skills would prepare a person to perform ina range of varied activities or knowledge application where there is a clearly defined range ofcontexts in which the choice of actions required is usually clear and there is limitedcomplexity in the range of operations to be applied.

Performance of a prescribed range of functions involving known routines and proceduresand some accountability for the quality of outcomes.

Applications may include some complex or non-routine activities involving individualresponsibility or autonomy and/or collaboration with others as part of a group or team.



• demonstrate basic operational knowledge in a moderate range of areas;• apply a defined range of skills;• apply known solutions to a limited range of predictable problems;• perform a range of tasks where choice between a limited range of options is required;• assess and record information from varied sources;• take limited responsibility for own outputs in work and learning.

Certificate III


Breadth, depth and complexity of knowledge and competencies would cover selecting,adapting and transferring skills and knowledge to new environments and providing technicaladvice and some leadership in resolution of specified problems. This would be appliedacross a range of roles in a variety of contexts with some complexity in the extent and choiceof options available.

Performance of a defined range of skilled operations, usually within a range of broaderrelated activities involving known routines, methods and procedures, where some discretionand judgement is required in the section of equipment, services or contingency measures



and within known time constraints.

Applications may involve some responsibility for others. Participation in teams includinggroup or team co-ordination may be involved.



• demonstrate some relevant theoretical knowledge• apply a range of well-developed skills• apply known solutions to a variety of predictable problems• perform processes that require a range of well-developed skills where some discretion

and judgement is required• interpret available information, using discretion and judgement• take responsibility for own outputs in work and learning• take limited responsibility for the output of others.

Certificate IV


Breadth, depth and complexity of knowledge and competencies would cover a broad rangeof varied activities or application in a wider variety of contexts most of which are complex andnon-routine. Leadership and guidance are involved when organising activities of self andothers as well as contributing to technical solutions of a non-routine or contingency nature.

Performance of a broad range of skilled applications including the requirement to evaluateand analyse current practices, develop new criteria and procedures for performing currentpractices and provision of some leadership and guidance to others in the application andplanning of the skills. Applications involve responsibility for, and limited organisation of,others.



• demonstrate understanding of a broad knowledge base incorporating some theoreticalconcepts

• apply solutions to a defined range of unpredictable problems• identify and apply skill and knowledge areas to a wide variety of contexts, with depth in

some areas• identify, analyse and evaluate information from a variety of sources• take responsibility for own outputs in relation to specified quality standards• take limited responsibility for the quantity and quality of the output of others.

Diploma


Breadth, depth and complexity covering planning and initiation of alternative approaches toskills or knowledge applications across a broad range of technical and/or managementrequirements, evaluation and co-ordination.

The self directed application of knowledge and skills, with substantial depth in some areaswhere judgement is required in planning and selecting appropriate equipment, services andtechniques for self and others.

Applications involve participation in development of strategic initiatives as well as personal



responsibility and autonomy in performing complex technical operations or organising others.It may include participation in teams including teams concerned with planning and evaluationfunctions. Group or team co-ordination may be involved.

The degree of emphasis on breadth as against depth of knowledge and skills may varybetween qualifications granted at this level.


Do the competencies or learning outcomes enable an individual with this qualification to:

• demonstrate understanding of a broad knowledge base incorporating theoreticalconcepts, with substantial depth in some areas

• analyse and plan approaches to technical problems or management requirements• transfer and apply theoretical concepts and/or technical or creative skills to a range of

situations• evaluate information, using it to forecast for planning or research purposes• take responsibility for own outputs in relation to broad quantity and quality parameters• take some responsibility for the achievement of group outcomes.

Advanced Diploma


Breadth, depth and complexity involving analysis, design, planning, execution and evaluationacross a range of technical and/or management functions including development of newcriteria or applications or knowledge or procedures.

The application of a significant range of fundamental principles and complex techniquesacross a wide and often unpredictable variety of contexts in relation to either varied or highlyspecific functions. Contribution to the development of a broad plan, budget or strategy isinvolved and accountability and responsibility for self and others in achieving the outcomes isinvolved.

Applications involve significant judgement in planning, design, technical orleadership/guidance functions related to products, services, operations or procedures.

The degree of emphasis on breadth as against depth of knowledge and skills may varybetween qualifications granted at this level.


Do the competencies or learning outcomes enable an individual with this qualification to:

• demonstrate understanding of specialised knowledge with depth in some areas• analyse, diagnose, design and execute judgements across a broad range of technical

or management functions• generate ideas through the analysis of information and concepts at an abstract level• demonstrate a command of wide-ranging, highly specialised technical, creative or

conceptual skills• demonstrate accountability for personal outputs within broad parameters• demonstrate accountability for personal and group outcomes within broad parameters.

Vocational Graduate Certificate

Characteristics of competencies or learning outcomes

• The self-directed development and achievement of broad and specialised areas ofknowledge and skills, building on prior knowledge and skills.



• Substantial breadth and complexity involving the initiation, analysis, design, planning,execution and evaluation of technical and management functions in highly varied andhighly specialised contexts.

• Applications involve making significant, high-level, independent judgements in majorbroad or planning, design, operational, technical and management functions in highlyvaried and specialised contexts. They may include responsibility and broad rangingaccountability for the structure, management and output of the work or functions ofothers.

• The degree of emphasis on breadth, as opposed to depth, of knowledge and skills mayvary between qualifications granted at this level.

Distinguishing features of learning outcomes

• Demonstrate the self-directed development and achievement of broad and specialisedareas of knowledge and skills, building on prior knowledge and skills.

• Initiate, analyse, design, plan, execute and evaluate major broad or technical andmanagement functions in highly varied and highly specialised contexts.

• Generate and evaluate ideas through the analysis of information and concepts at anabstract level.

• Demonstrate a command of wide-ranging, highly specialised technical, creative orconceptual skills in complex contexts.

• Demonstrate responsibility and broad-ranging accountability for the structure,management and output of the work or functions of others.

Vocational Graduate Diploma

Characteristics of competencies or learning outcomes

• The self-directed development and achievement of broad and specialised areas ofknowledge and skills, building on prior knowledge and skills.

• Substantial breadth, depth and complexity involving the initiation, analysis, design,planning, execution and evaluation of major functions, both broad and highlyspecialised, in highly varied and highly specialised contexts.

• Further specialisation within a systematic and coherent body of knowledge.• Applications involve making high-level, fully independent, complex judgements in broad

planning, design, operational, technical and management functions in highly varied andhighly specialised contexts. They may include full responsibility and accountability forall aspects of work and functions of others, including planning, budgeting and strategydevelopment.

• The degree of emphasis on breadth, as opposed to depth, of knowledge and skills mayvary between qualifications granted at this level.

Distinguishing features of learning outcomes

• Demonstrate the self-directed development and achievement of broad and highlyspecialised areas of knowledge and skills, building on prior knowledge and skills.

• Initiate, analyse, design, plan, execute and evaluate major functions, both broad andwithin highly varied and highly specialised contexts.

• Generate and evaluate complex ideas through the analysis of information and conceptsat an abstract level.

• Demonstrate an expert command of wide-ranging, highly specialised, technical,creative or conceptual skills in complex and highly specialised or varied contexts.

• Demonstrate full responsibility and accountability for personal outputs.• Demonstrate full responsibility and accountability for all aspects of the work or functions

of others, including planning, budgeting and strategy.



Qualification pathways - Food Processing

FDF03 Food Processing Training Package is the framework for VET for those engaged in thefood processing and pharmaceutical manufacturing industries. The Training Packagesupports a wide range of learning pathways. These include institution-based programs,workplace and school-based training, as well as other flexible combinations of workplace andoff-the-job training and assessment.

Qualifications within FDF03 Food Processing Training Package can be achieved through avariety of pathways including new apprenticeships (traineeships). The training pathways forqualifications contained within FDF03 Food Processing Training Package are illustratedbelow. For further advice about pathways and qualifications contact the Agri-food IndustrySkills Council on telephone 02 6163 7200 or email [email protected] .

Pathways

An employee/person may enter directly into a qualification at AQF levels 1, 2, 3, 4 or 5.

Credit for units completed in a lower level qualification can be counted towards a higher levelqualification within the given packaging rules.

Australian apprenticeship arrangements

All qualifications within the Package are open to Australian apprenticeship pathways.Australian apprenticeship arrangements already exist for all qualifications within this TrainingPackage with the exception of the Certificates in Food Processing (Sales). Discussions withthe relevant industrial parties will need to occur. However, it is expected that Australianapprenticeship arrangements will be established for this new area.

VET in schools delivery

The Certificates in Food Processing and related qualifications have the potential to be usedas a VET in schools program. This is conditional on local parties collaborating to agree ondelivery, assessment and infrastructure arrangements. Models for these arrangements areestablished in the food processing industry. For information contact the Agri-food IndustrySkills Council on telephone 02 6163 7200 or email [email protected].

Structure of the Food Processing Industry Qualifications

The structure of these qualifications is outlined below.

Types of units

Different types of units make up these qualifications. They are Core, Specialist and Optionalunits. Additional units may be imported for other Training Packages as required.

Core units

Core units are prescribed for all qualifications within this Training Package. These units coverskills and knowledge integral to work in the food processing industry. Employees must haveattained competence in the relevant core units before, or concurrent with, achievingcompetence in any specialist or optional unit/s. Core units are a compulsory component ofeach food processing qualification. Note that the core units are stand-alone units. This meansthat the appropriate Core units can be selected to align to the level of work performed.

The pharmaceutical manufacturing qualifications share some common units with the foodprocessing Core but also include Core units in Good Manufacturing Practice. These GMP



mailto:[email protected]

units have been specifically designed for use within the pharmaceutical industry.

Specialist units

These are units of competency that are directly associated with the main job-based activitiesperformed in the workplace.

Specialist units are defined for Certificate I-III and are process-based. A guiding principle inthe review of this Training Package has been to remove unit duplication. This has resulted ina significant reduction of sector-specific units and a corresponding increase in cross-sectorspecialist or multi-sector Specialist units.

To support ready identification of units by function, multi-sector Specialist units have beencategorised in the following way:

• FDFZCS Cleaning and sanitation units• FDFZMH Materials handling units• FDFZPM Preparation and mixing units• FDFZPR Production/processing units• FDFZPK Packaging units

Specialist units include those developed specifically for the food processing industry andrelevant units that have been imported from other Training Packages. Imported units retaintheir own codes such as:

• TDT Warehousing• WRR Retail• PRM Specialist cleaning• THH Tourism/Hospitality• SUG Sugar Milling

• PMB/PMA Process Manufacturing• RUA Rural• PSP Public Service• PML Laboratory• BSB/BSZ Business Services

For ease of locating, Certificate IV and Diploma level specialist units have been broken downinto two main categories:

• Food processing• Pharmaceutical.

Food processing Certificate IV and Diploma level Specialist units have been grouped bygeneral activity:

• FDFPL - Planning• FDFIM - Information management• FDFPM - People management/Workplace relationships• FDFPI - Process improvement• FDFTEC - Technical• FDFFS - Food Safety Auditing.

No additional Core or Optional units are aligned at Certificate IV and Diploma levels for Foodprocessing. Units at these qualifications levels are simply referred to as Specialist units.

Optional units

These units may be used as appropriate to meet work requirements. They cover areas suchas training and assessment, environmental practices/procedures, teamwork, pest prevention,maintenance, and sampling and testing. Some imported units are listed as optional units.

Additional units

The units listed in this Training Package are designed to meet typical food processing industry



work requirements. If these units cannot meet any specific enterprise requirements, then unitsfrom any other registered Training Packages may be imported.

Note that imported units from other Training Packages should not duplicate the content ofunits already included. For the purposes of the qualification packaging arrangements,additional imported units should be treated as optional units.

Typically these units align at the same AQF level as their alignment in the source TrainingPackage

There is a limit to the number of additional units that can be counted towards a qualification atCertificate IV and Diploma levels. Refer to the Packaging rules for qualifications on Page 23.

Duplication between units

FDF qualifications cover diverse industry sectors and units have been developed over time,often in parallel with other related training packages. An underpinning principle of qualificationpackaging rules is to avoid selecting units which duplicate content. The following guidance isprovided to assist RTOs when structuring qualifications.

Selection of GMP units. GMP units are specifically designed for application in pharmaceuticalmanufacturing environments where food-related qualify and food safety requirements areinappropriate. As some companies have indicated a commitment to GMP, it should be notedthat there is a direct duplication between GMP, and quality assurance and food safety units. Itis therefore not appropriate to adopt the pharmaceutical sector GMP units in addition to thesetwo food processing core units.

Some units such as FDFZPRPR2A Operate a production process and FDFZPKPP2A Operatea packaging process are generic units that can be used where no process-specific unit exists.These units cannot be used in addition to an existing process-specific unit if this results indouble-counting of units to cover the same competency.

The small business units (aligned at Certificate III) cover similar areas as FDF and BSB unitsaligned at Certificate IV and Diploma levels. The small business units are specificallydesigned to address this target audience. The guiding principle is that no more than one unitcan be used to cover the same area of competence. Where more than one unit could apply,the unit content needs to be considered to determine unit selection.

In some cases generic management units at Certificate IV and Diploma level have beenrevised to reflect application in a food processing context. When importing units, particularly atCertificate IV and Diploma levels, the imported unit should not duplicate the content of anexisting unit.

The table below summarises duplicate units within the Pharmaceutical Manufacturingqualifications at AQF IV and V.

Unit Duplicating unit

MEM15.1AA Perform basic statistical qualitycontrol

FDFOPTSPC2A Apply principles of statisticalprocess control

MCMT261A Use SCADA systems inmanufacturing

FDFZPRCI2A Operate a process controlinterface

The addition of specific units for conducting food safety audits should be noted. FDFIMMIA4AManage internal audits should only be selected to support audits related to quality, health andsafety and environmental management. Where the internal audit relates to food safety, selecteither FDFFSACA Assess compliance with food safety programs or FDFFSCFSAA Conductfood safety audits, according to the level of auditing competence required.



Coding of units of competency

Each Training Package is assigned a unique five character code. For this version of therevised Food Processing Training Package, it is FDF03. Each unit of competency is alsoassigned a code of up to 12 characters, consisting of capital letters and numbers.

The first three letters of the code are taken from the Training Package code FDF. The next2-3 letters indicate the type of unit and/or industry sector:

• COR indicates that the unit is a core competency standard.• Z indicates that the unit applies across industry sectors (refer to earlier Z unit code

descriptors).• OPT indicates that the unit is part of the optional set of units.• PH indicates that the unit applies to the Pharmaceutical sector.

The last 2-3 letters represent the title of the unit. The first number indicates the AQF levelwhere the unit typically aligns. The final letter indicates the unit version.

Units listed at more than one AQF Level

Some units are listed at more than one AQF level. Listing units at more than one AQF levelreflects common industry application.

At the Certificate IV and Diploma levels, the industry had great difficulty in assigning units adiscrete AQF level. Some units were clearly of such complexity, breadth and depth that theycould easily be aligned to AQF 5. However, some units could apply at either level dependingon the company size and/or work practices employed and these have been listed at bothlevels.

A number of units have been included from other Training Packages to address typicalcompetency requirements in the food processing industry. Typically these units align at thesame AQF level as their alignment in the source Training Package. In some cases, however,industry application required realignment of these units to reflect industry practice.

Qualification pathways - Wine Industry

An employee/person may enter directly into a Certificate I, II or III in Food Processing (Wine).Credit for units completed in a lower level qualification can be transferred and countedtowards a higher level qualification. Refer to the diagram below.

New Apprenticeship Arrangements

All qualifications within the Package are open to New Apprenticeship pathways.

VET in Schools Delivery

The Certificates in Food Processing (Wine) have the potential to be used as a VET in Schoolsprogram. This is conditional on local parties collaborating to agree on delivery, assessmentand infrastructure arrangements. Models for these arrangements are established in the foodprocessing industry. For information contact the National Food Industry Training Council.

Components of the Wine Industry Qualifications

Different types of Units of Competency make up these qualifications. The Units ofCompetency have been classified into Core, Specialist and Optional groups. This structuretakes into account the acquisition and application of industry-wide, sector and enterpriseknowledge and skills.



Core Units

These are units that are compulsory in qualifications for all sectors of the food processingindustry. They cover communication, food safety, numeracy, occupational health and safetyand quality assurance.

Perform Effectively in the Workplace is a unit that is compulsory for Wine Industryqualifications. It covers a basic employee induction into the wine production workplace.

Specialist Units

Specialist units are competency standards that are directly associated with:

• bottling and packaging• cellar door sales• cellar operations• laboratory operations• warehouse and distribution• wine grape growing.

They can be selected in any combination within the packaging requirements for a givenqualification.

Where there are relevant competency standards in other industry Training Packages, thesehave been included in the Wine Sector Training Package. In some cases the Unit ofCompetency has been inserted in its original (source) format to facilitate future upgradeswhen other Training Packages are reviewed.

Optional Units

Optional units are competency standards from other industry Training Packages that supportthe Wine Industry Specialist units. They have been allocated a pool and points for use withinthis Training Package.

Pools

Units of Competency have been aligned to the AQF and then grouped into Pools 1, 2 or 3.(Pool 1 closely equates to AQF level 1, Pool 2 to AQF level 2 and Pool 3 to AQF level 3.) Theallocation of units to Pools reflects the differences in the nature and complexity of skills andknowledge used within the industry. Some units have therefore been listed in more than onepool to reflect workplace practices where particular competencies apply to more than oneoccupation or classification level.

Points

Each Unit of Competency has been allocated a value of 2, 4, or 6 points. Points have beenallocated based on three factors:

• the amount of training required• the amount of underpinning knowledge and experience required to achieve competency• the complexity of skill required. For example does it involve simply following procedures

or more complex tasks such as prioritising and problem solving.

For a full list of the unit pools and points that have been allocated refer to the Index of Units.

The Core Units of Competency do not have points allocated to individual units because theyare a compulsory component of each qualification. Instead, a pre-determined value has beenallocated (12 points at each qualification level) on the successful completion of the Core units.



Packaging of Wine Industry Qualifications

Principles for Packaging Units of Competency

The NFITC has established the following principles for packaging Units of Competency intoqualifications in the food processing industry:

• packaging supports existing classifications within industrial agreements• packaging facilitates industrial parties to develop and implement future industrial

agreements• packaging provides maximum flexibility/choice in job design in the workplace• packaging maintains the integrity of the food processing industry's national certificate

and diploma qualifications.

Consistent with these principles, the wine sector Units of Competency have been aligned tothe AQF and then grouped into Pools 1, 2 or 3. Some units have been listed in more than onepool to reflect workplace practices. Each unit has also been allocated a point value.

The Units of Competency are packaged to a qualification level according to the needs of theindustry and in the context of industrial arrangements and agreements. The main criterion hasbeen to match groups of units to the AQF descriptors, work levels, career paths and typicalcompetency profiles within each work level.

Entry to Qualifications

Each AQF level has a qualification in its own right. A person may enter directly into any level.Each level addresses the occupational requirements within the context of the AQF descriptorsdescribed in the section outlining the Australian Qualification Framework system.

Prerequisites

Prerequisites to some Units of Competency are specified where there are essential skillsrequired to perform the tasks in the unit, that are not dealt with within the unit. In these cases,the Unit that covers the required essential skills is identified as a prerequisite.

Where a prerequisite is specified then the requirements must be met prior to assessment inthe unit which is being undertaken. Prerequisites can be achieved by recognition of currentcompetency or through a learning program to bridge any gaps in competency.

Prerequisite unit points are credited towards the qualification level and must be undertakenwithin the packaging requirements of the particular certificate.

Skill Sets

Definition

Skill sets are defined as single units of competency, or combinations of units of competencyfrom an endorsed Training Package, which link to a licence or regulatory requirement, ordefined industry need.

Wording on Statements of Attainment

Skill sets are a way of publicly identifying logical groupings of units of competency which meetan identified need or industry outcome. Skill sets are not qualifications.

Where skill sets are identified in a Training Package, the Statement of Attainment can set outthe competencies a person has achieved in a way that is consistent and clear for employersand others. This is done by including the wording 'these competencies meet [the relevant skillset title or industry need is included]' on the Statement of Attainment. This wording applies



only to skill sets that are formally identified as such in the endorsed Training Package.

All Statements of Attainment must include the wording 'A Statement of Attainment is issuedby a Registered Training Organisation when an individual has completed one or more units ofcompetency from a nationally recognised qualification'. The following may also be used 'thesecompetencies form part of the [the relevant qualification(s) code and title are inserted]'.

This section below provides information on skill sets within this Training Package, with thefollowing important disclaimer: Readers should ensure that they have also read the part ofthe Training Package that outlines licensing and regulatory requirements.

Skill Sets in this Training Package

Skill sets in this Training Package

Where this section is blank, nationally recognised skill sets have yet to be identified in thisindustry.



Assessment Guidelines

Introduction

These Assessment Guidelines provide the endorsed framework for assessment of units ofcompetency in this Training Package. They are designed to ensure that assessment isconsistent with the Australian Quality Training Framework (AQTF) Standards for RegisteredTraining Organisations. Assessments against the units of competency in this TrainingPackage must be carried out in accordance with these Assessment Guidelines.

Assessment System Overview

This section provides an overview of the requirements for assessment when using thisTraining Package, including a summary of the AQTF requirements; licensing/registrationrequirements; and assessment pathways.

Benchmarks for Assessment

Assessment within the National Training Framework is the process of collecting evidence andmaking judgements about whether competency has been achieved to confirm whether anindividual can perform to the standards expected in the workplace, as expressed in therelevant endorsed unit of competency.

In the areas of work covered by this Training Package, the endorsed units of competency arethe benchmarks for assessment. As such, they provide the basis for nationally recognisedAustralian Qualifications Framework (AQF) qualifications and Statements of Attainmentissued by Registered Training Organisations (RTOs).

Australian Quality Training Framework Assessment Requirements

Assessment leading to nationally recognised AQF qualifications and Statements ofAttainment in the vocational education and training sector must meet the requirements of theAQTF as expressed in the Standards for Registered Training Organisations.

The Standards for Registered Training Organisations can be downloaded from the DESTwebsite at www.dest.gov.au or can be obtained in hard copy from DEST. The following pointssummarise the assessment requirements under the AQTF.

Registration of Training Organisations

Assessment must be conducted by, or on behalf of, an RTO formally registered by a State orTerritory Registering/Course Accrediting Body in accordance with the Standards forRegistered Training Organisations. The RTO must have the specific units of competencyand/or AQF qualifications on its scope of registration. See Section 1 of the Standards forRegistered Training Organisations.

Quality Training and Assessment

Each RTO must have systems in place to plan for and provide quality training andassessment across all its operations. See Standard 1 of the Standards for RegisteredTraining Organisations.

Assessor Competency Requirements

Each person involved in training, assessment or client service must be competent for thefunctions they perform. See Standard 7 of the Standards for Registered TrainingOrganisations for assessor competency requirements. Standard 7 also specifies thecompetencies that must be held by trainers.

FDF03 Food Processing Industry Training Package (Version 3) Date this PDF was generated: 08 November 2007Assessment Guidelines


Assessment Requirements

The RTOs assessments must meet the requirements of the endorsed components of TrainingPackages within its scope of registration. See Standard 8 of the Standards for RegisteredTraining Organisations.

Assessment Strategies

Each RTO must identify, negotiate, plan and implement appropriate learning and assessmentstrategies to meet the needs of each of its clients. See Standard 9 of the Standards forRegistered Training Organisations.

Mutual Recognition

Each RTO must recognise the AQF qualifications and Statements of Attainment issued byany other RTO. See Standard 5 of the Standards for Registered Training Organisations.

Access and Equity and Client Services

Each RTO must apply access and equity principles, provide timely and appropriateinformation, advice and support services that assist clients to identify and achieve desiredoutcomes. This may include reasonable adjustment in assessment. See Standard 6 of theStandards for Registered Training Organisations.

Partnership Arrangements

RTOs must have, and comply with, written agreements with each organisation providingtraining and/or assessment on its behalf. See Standard 1.6 of Standards for RegisteredTraining Organisations.

Recording Assessment Outcomes

Each RTO must have effective administration and records management procedures in place,and must record AQF qualifications and Statements of Attainment issued. See Standards 4and 10.2 of the Standards for Registered Training.

Issuing AQF Qualifications and Statement of Attainment

Each RTO must issue AQF qualifications and Statements of Attainment that meet therequirements of the AQF Implementation Handbook and the endorsed Training Packageswithin the scope of its registration. An AQF qualification is issued once the full requirementsfor a qualification, as specified in the nationally endorsed Training Package are met. AStatement of Attainment is issued where the individual is assessed as competent againstfewer units of competency than required for an AQF qualification. See Standard 10 andSection 2 of the Standards for Registered Training Organisations.

Licensing/registration requirements

This section provides information on licensing/registration requirements for this TrainingPackage, with the following important disclaimer.

Licensing and registration requirements that apply to specific industries, and vocationaleducation and training, vary between each State and Territory, and can regularly change. Thedevelopers of this Training Package, and DEST, consider that the licensing/registrationrequirements described in this section apply to RTOs, assessors or candidates with respect tothis Training Package. While reasonable care has been taken in its preparation, thedevelopers of this Training Package and DEST cannot guarantee that the list is definitive oraccurate at the time of reading; the information in this section is provided in good faith on thatbasis.

Contact the relevant state or territory department(s) to check if the licensing/registration



requirements described below still apply, and to check if there are any others with which youmust comply. For further information contact www.agrifoodskills.net.au.

Requirements for assessors

In order to conduct assessment for statutory licensing or other industry registrationrequirements, assessors must meet the requirements outlined below, in addition to the AQTFrequirements.

Some individual units of competency may be subject to licensing arrangements beforetraining is commenced or before undertaking related work in the industry. Other units mayrequire licences for those responsible for delivery and assessment. Competency standardswhere licensing arrangements may be relevant include those dealing with:

• turbine and boiler operation• forklift operation• application of pesticides• working in confined spaces.

For further information on licensing requirements, refer to the National Occupational Healthand Safety Commission Standard: National Occupational Health and Safety CertificationStandard for Users and Operators of Industrial Equipment [NOHSC:1006 (2001)] and[NOHSC:7019 (1992)] and the NOHSC website at www.nohsc.gov.au .

When assessing an area covered by a licence, the assessment must be conducted accordingto the requirements of the managing authority and according to the Assessment Guidelinescontained within this Training Package. In the case of certificated occupations managed byNOHSC, assessment must be carried out by a certificated assessor in accordance withNOHSC guidelines. Interpretation and implementation of these guidelines are theresponsibility of the relevant state or territory health and safety authority.

Assessors of food safety auditors may need to meet additional certification requirementsdepending on the nature of the food safety auditing scheme. Refer to information within therelevant units and also see the Agri-foods Industry Skills website for information on foodsafety auditing qualifications, www.agrifoodskills.net.au .

Individuals conducting assessments of units that cover statutory licensing and industryregistration arrangements must comply with training, experience and registrationrequirements additional to the minimum requirements identified in this Training Package.

Requirements for RTOs

Selected units of competency and qualifications in this Training Package provide the basis fora range of statutory licensing and industry registration arrangements. To satisfy theselicensing and registration arrangements, RTOs must meet those additional requirements.

Requirements for candidates

Individuals being assessed under statutory licensing and industry registration systems mustcomply with training and experience requirements additional to the minimum requirementsidentified in this Training Package. This applies specifically to food safety auditor candidates.

Pathways

The competencies in this Training Package may be attained in a number of ways includingthrough:

• formal or informal education and training• experiences in the workplace



http://www.nohsc.gov.au


• general life experience, and/or• any combination of the above.

Assessment under this Training Package leading to an AQF qualification or Statement ofAttainment may follow a learning and assessment pathway, an assessment-only orrecognition pathway, or a combination of the two as illustrated in the following diagram.

Each of these assessment pathways leads to full recognition of competencies held - thecritical issue is that the candidate is competent, not how the competency was acquired.

Assessment, by any pathway, must comply with the assessment requirements set out in theStandards for Registered Training Organisations.

Learning and Assessment Pathways

Usually, learning and assessment are integrated, with assessment evidence being collectedand feedback provided to the candidate at anytime throughout the learning and assessmentprocess.

Learning and assessment pathways may include structured programs in a variety of contextsusing a range of strategies to meet different learner needs. Structured learning andassessment programs could be: group-based, work-based, project-based, self-paced, actionlearning-based; conducted by distance or e-learning; and/or involve practice and experiencein the workplace.

Learning and assessment pathways to suit New Apprenticeships have a mix of formalstructured training and structured workplace experience with formative assessment activitiesthrough which candidates can acquire and demonstrate skills and knowledge from therelevant units of competency.

Assessment-Only or Recognition of Prior Learning Pathway

Competencies already held by individuals can be formally assessed against the units ofcompetency in this Training Package, and should be recognised regardless of how, when orwhere they were achieved.

In an assessment-only or Recognition of Prior Learning (RPL) pathway, the candidateprovides current, quality evidence of their competency against the relevant unit ofcompetency. This process may be directed by the candidate and verified by the assessor,such as in the compilation of portfolios; or directed by the assessor, such as throughobservation of workplace performance and skills application, and oral and/or writtenassessment. Where the outcomes of this process indicate that the candidate is competent,structured training is not required. The RPL requirements of Standard 8.2 of the Standards forRegistered Training Organisations must be met.

As with all assessment, the assessor must be confident that the evidence indicates that thecandidate is currently competent against the endorsed unit of competency. This evidencemay take a variety of forms and might include certification, references from past employers,testimonials from clients, and work samples. The onus is on candidates to provide sufficientevidence to satisfy assessors that they currently hold the relevant competencies. In judgingevidence, the assessor must ensure that the evidence of prior learning is:

• authentic (the candidates own work)• valid (directly related to the current version of the relevant endorsed unit of competency)• reliable (shows that the candidate consistently meets the endorsed unit of competency)• current (reflects the candidates current capacity to perform the aspect of the work

covered by the endorsed unit of competency), and• sufficient (covers the full range of elements in the relevant unit of competency and

addresses the four dimensions of competency, namely task skills, task management



skills, contingency management skills, and job/role environment skills).

The assessment only or recognition of prior learning pathway is likely to be most appropriatein the following scenarios:

• candidates enrolling in qualifications who want recognition for prior learning or currentcompetencies

• existing workers• individuals with overseas qualifications• recent migrants with established work histories• people returning to the workplace, and• people with disabilities or injuries requiring a change in career.

Combination of Pathways

Where candidates for assessment have gained competencies through work and lifeexperience and gaps in their competence are identified, or where they require training in newareas, a combination of pathways may be appropriate.

In such situations, the candidate may undertake an initial assessment to determine theircurrent competency. Once current competency is identified, a structured learning andassessment program ensures that the candidate acquires the required additionalcompetencies identified as gaps.

Assessor Requirements

This section identifies the mandatory competencies for assessors, and clarifies how othersmay contribute to the assessment process where one person alone does not hold all therequired competencies.

Assessor Competencies

The Standards for Registered Training Organisations specify mandatory competencyrequirements for assessors. For information, Standard 7.3 from the Standards for RegisteredTraining Organisations follows:

7.3 a The RTO must ensure that assessments are conducted by a person who has:

• the following competencies* from the Training Package for Assessment andWorkplace Training, or demonstrated equivalent competencies:• TAAASS401A Plan and organise assessment;• TAAASS402A Assess competence;• TAAASS404A Participate in assessment validation;

• relevant vocational competencies, at least to the level being assessed.

b However, if a person does not have all of the competencies in Standards 7.3 a (i)and the vocational competencies as defined in 7.3 a (ii), one person with thecompetencies listed in Standard 7.3 a (i), and one or more persons who have thecompetencies listed in Standard 7.3 a (ii) may work together to conductassessments.

* A person who holds the competencies BSZ401A Plan assessment, BSZ402AConduct assessment, and BSZ403A Review assessment from the TrainingPackage for Assessment and Workplace Training will be accepted for the purposesof this standard. A person who has demonstrated equivalent competencies toBSZ401A and BSZ402A and BSZ403A in the period up to 12 months followingpublication of the Training and Assessment Training Package will also be acceptedfor the purposes of this standard.



Designing Assessment Tools

This section provides an overview on the use and development of assessment tools.

Use of Assessment Tools

Assessment tools provide a means of collecting the evidence that assessors use in makingjudgements about whether candidates have achieved competency.

There is no set format or process for the design, production or development of assessmenttools. Assessors may use prepared assessment tools, such as those specifically developed tosupport this Training Package, or they may develop their own.

Using Prepared Assessment Tools

If using prepared assessment tools, assessors should ensure these are benchmarked, ormapped, against the current version of the relevant unit of competency. This can be done bychecking that the materials are listed on the National Training Information Service(http://www.ntis.gov.au). Materials on the list have been noted by the National Training QualityCouncil as meeting their quality criteria for Training Package support materials.

Developing Assessment Tools

When developing assessment tools, assessors must ensure that they:

• are benchmarked against the relevant unit or units of competency• are reviewed as part of the validation of assessment strategies as required under 9.2 (i)

of the Standards for Registered Training Organisations• meet the assessment requirements expressed in the Standards for Registered Training

Organisations, particularly Standards 8 and 9.

A key reference for assessors developing assessment tools is TAA04 Training andAssessment Training Package and the unit of competency TAAASS403A Developassessment tools. There is no set format or process for the design, production ordevelopment of assessment materials.

Conducting Assessment

This section details the mandatory assessment requirements and provides information onequity in assessment including reasonable adjustment.

Mandatory Assessment Requirements

Assessments must meet the criteria set out in Standard 8 from the Standards for RegisteredTraining Organisations. For information, Standard 8 from the Standards for RegisteredTraining Organisations is reproduced below.

8 RTO Assessments

The RTOs assessments meet the requirements of the endorsed components ofTraining Packages and the outcomes specified in accredited courses within thescope of its registration.

8.1 The RTO must ensure that assessments (including RPL):

i. comply with the assessment guidelines included in the applicable nationallyendorsed Training Packages or the assessment requirements specified inaccredited courses;



ii. lead to the issuing of a statement of attainment or qualification under the AQF whena person is assessed as competent against nationally endorsed unit(s) ofcompetency in the applicable Training Package or modules specified in theapplicable accredited course;

iii. are valid, reliable, fair and flexible;

iv. provide for applicants to be informed of the context and purpose of the assessmentand the assessment process;

v. where relevant, focus on the application of knowledge and skill to standard ofperformance required in the workplace and cover all aspects workplaceperformance, including task skills, task management skills, contingencymanagement skills and job role environment skills;

vi. involve the evaluation of sufficient evidence to enable judgements to be madeabout whether competency has been attained;

vii. provide for feedback to the applicant about the outcomes of the assessmentprocess and guidance on future options in relation to those outcomes;

viii. are equitable for all persons, taking account of individual needs relevant to theassessment; and

ix. provide for reassessment on appeal.

8.2 a The RTO must ensure that RPL is offered to all applicants on enrolment

b The RTO must have an RPL process that:

i. is structured to minimise the time and cost to applicants; and

ii. provides adequate information, support and opportunities for participants toengage in the RPL process.

Access and Equity

An individuals access to the assessment process should not be adversely affected byrestrictions placed on the location or context of assessment beyond the requirementsspecified in this Training Package.

Reasonable adjustments can be made to ensure equity in assessment for people withdisabilities. Adjustments include any changes to the assessment process or context that meetthe individual needs of the person with a disability, but do not change competency outcomes.Such adjustments are considered reasonable if they do not impose an unjustifiable hardshipon a training provider or employer. When assessing people with disabilities, assessors areencouraged to apply good practice assessment methods with sensitivity and flexibility.

Assessment in the Food Processing Industry

Assessing Competency

The assessor and candidate need to mutually implement agreed processes that will result in avalid, reliable, fair, flexible, sufficient, and authentic assessment of workplace competency.

The following points outline key reminders in relation to the assessment of competency. Formore comprehensive information, refer to the Assessment Guidelines section.



Principles

Assessments must meet the assessor competency standards Plan assessment, Conductassessment and Review assessment.

Assessment must include all Elements of the Unit of Competency being assessed. Thisincludes all items in the Performance criteria and Evidence requirements.

If a simulated environment is to be used for assessment, it must be as close to the workplacecontext as possible, so that the assessment is a valid, reliable and fair indication ofcompetency in the real workplace. The equipment, procedures and documentation should bethose typically used in a workplace.

Assessment should not require a higher level of communication competency than thatspecified in the Core competencies for the particular AQF level.

Assessment should reinforce the integration of the key competencies and the food industry'sCore competencies for the particular AQF level.

Process

The assessment process should be negotiated by the assessor and candidate so that bothparties have confidence in the process and its outcomes.

Self-assessment by the candidate should be integrated into the assessment processwherever possible.

All employees directly or indirectly involved in the process should be briefed on the factorsthat will impact on them, eg duration, changes in work routine.

Practice

Assessment should be over time and a range of events to ensure that the candidate canconsistently demonstrate authentic performance.

Evidence-gathering methods must be appropriate to the context, the assessor and thecandidate. The methods used to collect evidence must meet the principles of validity, equity,authenticity and sufficiency.

The following is a list of common methods for gathering evidence. It is by no meansexhaustive. It is generally advisable that at least two methods be used to ensure reliability.

• Workplace performance• Simulation• Role-play• Questioning (oral or written)• Visual presentation• Work-based assignment or project• Skills folio, demonstrating prior experience• Third party reports

Following the assessment process, assessment outcomes need to be recorded and feedbackprovided in terms of performance against the competency standards.

Further Sources of Information

The section provides a listing of useful contacts and resources to assist assessors inplanning, designing, conducting and reviewing of assessments against this Training Package.

Contacts



ContactsAgri-food Industry Skills Council

7 National Circuit

BARTON ACT 2600

PO Box 5450

KINGSTON ACT 2604

Telephone: (02) 6163 7200

Fax: (02) 6163 7278

Web: www.agrifoodskills.net.au

Email: [email protected]

Australian Training Products Ltd

Level 25, 150 Lonsdale Street

MELBOURNE VIC 3000

PO Box 12211

A'Beckett Street Post Office

MELBOURNE VIC 8006

Telephone: (03) 9655 0600

Fax: (03) 9639 4684

Web: www.atpl.net.au


Innovation and Business Industry Skills Council

Building B, Level 2

192 Burwood Road

Telephone: (03) 9815 7000

Fax: (03) 9815 7001


General Resources

Refer to http://antapubs.dest.gov.au/publications/search.asp to locate the following ANTApublications.

AQF Implementation Handbook, third Edition. Australian Qualifications Framework AdvisoryBoard, 2002, aqf.edu.au

Australian Quality Training Framework (AQTF) - for general information go to:www.dest.gov.au/sectors

Australian Quality Training Framework (AQTF) - for resources and information go to:www.dest.gov.au

Australian Quality Training Framework Standards for Registered Training Organisations,Australian National Training Authority, Melbourne, 2005. Available in hard copy from State




mailto:[email protected]

http://antapubs.dest.gov.au/publications/search.asp

http://www.aqf.edu.au

http://www.dest.gov.au/sectors


and Territory Training Authorities or can be downloaded from www.dest.gov.au

TAA04 Training and Assessment Training Package. This is available from the Innovation andBusiness Skills Australia (IBSA) Industry Skills Council and can be viewed, and componentsdownloaded, from the National Training Information Service (NTIS). National TrainingInformation Service, an electronic database providing comprehensive information aboutRTOs, Training Packages and accredited courses - www.ntis.gov.auStyle Guide for TrainingPackage Support Materials, Australian National Training Authority, Melbourne, 2003. Can bedownloaded from the ANTA page at www.dest.gov.au

Assessment Resources

Training Package Assessment Guides - a range of resources to assist RTOs in developingTraining Package assessment materials developed by DEST with funding from theDepartment of Education, Training and Youth Affairs. It is made up of 10 separate titles, asdescribed at the ANTA publications page of www.dest.gov.au. Go towww.resourcegenerator.gov.au/loadpage.asp?TPAG.htm

Printed and/or CD ROM versions of the Guides can be purchased from Australian TrainingProducts (ATP). The resource includes the following guides:

• Training Package Assessment Materials Kit• Assessing Competencies in Higher Qualifications• Recognition Resource• Kit to Support Assessor Training• Candidates Kit: Guide to Assessment in New Apprenticeships• Assessment Approaches for Small Workplaces• Assessment Using Partnership Arrangements• Strategies for ensuring Consistency in Assessment• Networking for Assessors• Quality Assurance Guide for Assessment

An additional guide "Delivery and Assessment Strategies" has been developed tocomplement these resources.

Assessment Tool Design and Conducting Assessment

VETASSESS AND; Western Australian Department of Training and Employment 2000,Designing Tests - Guidelines for designing knowledge based tests for Training Packages.Vocational Education and Assessment Centre 1997, Designing Workplace Assessment Tools,A self-directed learning program, NSW TAFE.

Manufacturing Learning Australia 2000, Assessment Solutions, Australian Training Products,Melbourne.

Rumsey, David 1994, Assessment practical guide, Australian Government Publishing Service,Canberra.

Assessor Training

Australian Committee on Training Curriculum (ACTRAC) 1994, Assessor training program -learning materials, Australian Training Products, Melbourne.

Australian National Training Authority, A Guide for Professional Development, ANTA,Brisbane.

Australian Training Products Ltd Assessment and Workplace Training, Training Package -Toolbox, ATPL Melbourne.




http://www.ntis.gov.au



http://www.resourcegenerator.gov.au/loadpage.asp?TPAG.htm

Green, M, et al. 1997, Key competencies professional development Package, Department forEducation and Childrens Services, South Australia.

Victorian TAFE Association 2000, The professional development CD: A learning tool, VTA,Melbourne.

Assessment System Design and Management

Office of Training and Further Education 1998, Demonstrating best practice in VET project -assessment systems and processes, OTFE Victoria.

Toop, L., Gibb, J. and; Worsnop, P. Assessment system designs, Australian GovernmentPublishing Service, Canberra.

Western Australia Department of Training and VETASSESS 1998, Kit for Skills RecognitionOrganisations, WADOT, Perth.



FDFAWDMC2A Operate a deaeration, mixing and carbonationprocess

Unit Descriptor This is a Specialist unit. It covers the skills and knowledge required toset up, operate, adjust and shut down a process to deaerate, mix andcarbonate aerated drink products prior to filling.

Unit Sector Aerated Waters

ELEMENT PERFORMANCE CRITERIA

1. Prepare the equipmentand process for operation

1.1 Materials are confirmed and available to meet operatingrequirements

1.2 Cleaning and maintenance requirements and status areidentified and confirmed

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

1.4 Processing/operating parameters are entered as requiredto meet safety and production requirements

1.5 Equipment performance is checked and adjusted asrequired

1.6 Pre-start checks are carried out as required by workplacerequirements

2. Operate and monitor theprocess

2.1 The process is started and operated according toworkplace procedures

2.2 Equipment is monitored to identify variation in operatingconditions

2.3 Variation in equipment operation is identified andmaintenance requirements are reported according toworkplace reporting requirements

2.4 The process is monitored to confirm that specifications aremet at each stage

2.5 Out-of-specification product/process outcomes areidentified, rectified and/or reported to maintain the processwithin specification

2.6 The workplace meets housekeeping standards2.7 Workplace records are maintained according to workplace

recording requirements

3. Shut down the process 3.1 The appropriate shutdown procedure is identified3.2 The process is shut down according to workplace

procedures3.3 Maintenance requirements are identified and reported

according to workplace reporting requirements

FDF03 Food Processing Industry Training Package (Version 3) Date this PDF was generated: 08 November 2007

FDFAWDMC2A Operate a deaeration, mixing and carbonation process

Volume 2 of 5, Unit 1 of 140 Page 32 of 760© Commonwealth of Australia, 2007 To be reviewed by: 30 April 2006

RANGE STATEMENT

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

Range description • Work is carried out according to company policies andprocedures, regulatory and licensing requirements,legislative requirements, and industrial awards andagreements

• Legislative requirements are typically reflected inprocedures and specifications. Legislation relevant to thisindustry includes the Food Standards Code includinglabelling, weights and measures legislation; andlegislation covering food safety, environmentalmanagement, occupational health and safety,anti-discrimination and equal opportunity

• Workplace information may include Standard OperatingProcedures (SOPs), specifications, production schedulesand instructions, manufacturers' advice, standard formsand reports

• Equipment typically includes a deaerator, a continuousflow mixing process and a carbonator. Carbonation mayinclude both direct injection through pipework and/or gasabsorption under refrigerated and pressurised conditionsin a carbonator

• Operators carry out changeovers within workplacearrangements and the relevant changeover proceduresshould be used to customise the details of this unit.Where more detailed changeovers are carried out, alsorefer to FDFOPTCRM2A Conduct routine maintenance

• Shutdown procedures may include cleaning. In somecases cleaning may be carried out by a dedicatedcleaning crew

• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, refrigerant, carbon dioxide, water,vacuum/pressure, and compressed and instrumentationair




EVIDENCE GUIDE

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

Ability to: • Access workplace information to identify processingrequirements

• Select, fit and use personal protective clothing and/orequipment

• Confirm supply of necessary materials and services• Conduct pre-start checks. This may involve inspecting

equipment condition to identify any signs of wear;confirming operation of the vacuum pump on thedeaerator; setting orifice plate and vernier to deliver syrupand water in the required proportions to the mixer;checking supply of refrigerant and carbon dioxide; settingrequired temperature and pressure settings; cancellingisolation or lockouts as required; confirming thatequipment is clean and correctly configured forprocessing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required toconfirm process remains within specification.• On the deaerator, monitoring may include:

• water supply• vacuum pump operation• water level/vacuum level

• At the mixing state, monitoring may include:• correct blend ratio for product type• brix of the mix

• At the carbonation state, monitoring may include:• volume of carbon dioxide injected• temperature• speed of injection• testing carbonation of liquid

• Monitor supply and flow of materials to and from theprocess

• Take corrective action in response to out-of-specificationresults

• For a given syrup : water ratio, determine requiredoperating settings to achieve a given brix result

• Respond to and/or report equipment failure within level ofresponsibility

• Locate emergency stop functions on equipment• Follow isolation and lock out/tag out procedures as

required to take process and related equipment off-line inpreparation for cleaning and/or maintenance within levelof responsibility

• Demonstrate batch/product changeovers• Complete workplace records as required




• Maintain work area to meet housekeeping standards

May include ability to:

• Use process control systems• Conduct routine maintenance• Clean and sanitize equipment




Knowledge of: • Purpose and basic principles of each stage of theprocess. This includes an understanding of therelationships between variables such as pressure,temperature and volume on processing outcomes

• Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents, status and purpose of guards, equipmentoperating capacities and applications, and the purposeand location of sensors and related feedbackinstrumentation. It also includes knowledge of servicesrequired and action to take if services are not available

• The flow of this process and the effect of outputs ondownstream processes. This includes an understandingof how each stage of the process affects related stagesand how the outputs of this process affect the filling stage

• Quality characteristics to be achieved by each stage ofthe process. This includes an understanding of theamount of dissolved air to be removed at deaeration, thetypical water : syrup ratios for product types and thevolume of carbon dioxide to be dissolved in the aeratedproduct

• Quality and condition requirements of inputs and effect ofvariation on process performance. This may include anunderstanding of the characteristics of differentingredients and how they behave when processed. Forexample, the difference between processing productscontaining fruit juice compared with those that do not

• Operating requirements and parameters and correctiveaction required where operation is outside specifiedoperating parameters

• Typical equipment faults and related causes. Thisincludes recognition of signs and symptoms of faultyequipment and early warning signs of potential problems

• Methods used to monitor the production process. Thisincludes inspecting, measuring and testing as required bythe process. It requires awareness of inspection or testpoints (control points) in the process and the relatedprocedures and recording requirements. This includes anunderstanding of test procedures for brix and carbonationand other tests as required by the process

• Contamination/food safety risks associated with theprocess and related control measures

• Common causes of variation and corrective actionrequired

• OHS hazards and controls• Requirements of different shutdowns as appropriate to

the process and workplace production requirements. Thisincludes emergency and routine shutdowns andprocedures to follow in the event of a power outage

• Isolation, lock out and tag out procedures andresponsibilities

• Product/process changeover procedures andresponsibilities




• Procedures and responsibility for reporting productionand performance information

• Environmental issues and controls relevant to theprocess. This includes waste/rework collection andhandling procedures related to the process

May include knowledge of:

• Basic operating principles of process control whererelevant. This includes the relationship between controlpanels and systems and the physical equipment

• Routine maintenance procedures• Cleaning and sanitation procedures

Relationship with otherstandards

Pre-requisite units

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

Co-assessment of related units

This unit should be assessed together with core units and otherunits of competence relevant to the function or work role. Inaddition, the following optional or ancillary units may berelevant:

• FDFZPRCI2A Operate a process control interface• FDFOPTISP2A Apply sampling techniques• PMLTEST300A Perform basic tests• FDFOPTCRM2A Conduct minor routine maintenance• FDFZCSCIP2A Clean equipment in place• FDFZCSCS2A Clean and sanitize equipment

Resources required forassessment

Assessment must occur in a real or simulated workplace wherethe 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• Process and related equipment and services. This

includes refrigerant and carbon dioxide• Syrup, water and other 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




Assessment requirements For information on how to assess this competency standardand who can assess, refer to the Assessment Guidelines forthis Training Package.




FDFBISETP2A Manufacture extruded and toasted productsUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down an extrusion, toasting andbreaking process used in the manufacture of Cruskit products.

Unit Sector Biscuits


1. Prepare the extrusion,toasting and breakingprocess for operation







2. Operate and monitor theextrusion, toasting andbreaking process




2.4 The process is monitored to confirm that Cruskit productmeets specifications




3. Shut down the extrusion,toasting and breakingprocess

3.1 The appropriate shutdown procedure is identified3.2 The process is shut down according to workplace




FDFBISETP2A Manufacture extruded and toasted products


RANGE STATEMENT

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




• Equipment may include mixers, sieves, extrusion,toasting and breaking equipment

• Materials include pre-mixed dry ingredients and water• Operation of equipment and processes may require the

use of process control panels and systems• Operators carry out changeovers within workplace

arrangements and the relevant changeover proceduresshould be used to customise the details of this unit.Where more detailed changeovers are carried out, alsorefer to FDFOPTCRM2A Conduct routine maintenance


• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, steam, water, vacuum, and compressed andinstrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify extrusion,toasting and breaking process requirements


• Confirm supply of necessary materials and services. Thisincludes ensuring a continuous supply of ingredients tothe process

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat related equipment is clean and correctly configuredfor processing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational. In addition for extruder confirm:• water pump is operating• bin discharge speed settings• temperature and heater settings• motor speed settings• screw feed settings

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required toconfirm the process remains within specification. Thismay involve monitoring:• temperatures• biscuit size (width, length and thickness)• biscuit texture, colour and weight• biscuit moisture level• clean, even break/cut

• Monitor supply and flow of materials to and from theextrusion, toasting and breaking process


• Conduct batch/product changeovers• Respond to and/or report equipment failure within level of

responsibility• Locate emergency stop functions on equipment• Shut down equipment in response to an emergency

situation• Follow isolation and lock out/tag out procedures as

required to take extrusion, toasting and breaking processand related equipment off-line in preparation for cleaningand/or maintenance within level of responsibility

• Complete workplace records as required• Maintain work area to meet housekeeping standards





• Use process control systems• Clean and sanitize equipment• Take samples and conduct tests• Conduct routine maintenance




Knowledge of: • Purpose and basic principles of each stage of the Cruskitmanufacturing process


• The flow of this process and the effect of outputs ondownstream processes

• Changes which occur in product during processing• Quality characteristics to be achieved by the process• Quality requirements of materials and effect of variation

on process performance• Operating requirements and parameters and corrective

action required where operation is outside specifiedoperating parameters


• Methods used to monitor the production process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the processand the related procedures and recording requirements








May include knowledge of:• Basic operating principles of process control where

relevant. This includes the relationship between controlpanels and systems and the physical equipment

• Cleaning and sanitation procedures• Sampling and testing associated with process monitoring

and control• Routine maintenance requirements and procedures





Pre-requisite unitsThere are no pre-requisite units for this competency standard.

Co-assessment of related unitsThis unit should be assessed together with core units and otherunits of competence relevant to the function or work role. Inaddition, the following optional or ancillary units may berelevant:

• FDFZPRCI2A Operate a process control interface• FDFOPTISP2A Implement sampling procedures• PMLTEST300A Perform basic tests• FDFOPTCRM2A Conduct routine maintenance• FDFZCSCIP2A Clean equipment in place• FDFZCSCS2A Clean and sanitize equipment


Assessment must occur in a real or simulated workplace whereassessee has access to:



parameters• Production schedule and recipe/batch instructions• Extrusion, toasting and breaking process and related

equipment and services• Specifications, control points and processing parameters• Ingredients to be processed• Sampling schedules and test procedures and equipment



required





FDFBISFS2A Operate a forming/shaping processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a biscuit forming/shapingprocess.



1. Prepare the biscuitforming process foroperation

1.1 Materials and ingredients are confirmed and available tomeet operating requirements






2. Operate and monitor thebiscuit forming process




2.4 The process is monitored to confirm that formed product isproduced to specification




3. Shut down the biscuitforming process





FDFBISFS2A Operate a forming/shaping process


RANGE STATEMENT





• Equipment may include depositing, rolling, forming andcutting equipment; manual and automated weighing andmeasuring equipment; and conveying systems

• Operation of equipment and processes may require theuse of process control panels and systems







EVIDENCE GUIDE


Ability to: • Access workplace information to identify biscuit formingprocess requirements


• Confirm supply and condition of necessary materials andservices. This may include transferring and loading doughinto hoppers. Confirming condition of dough may involveconfirming:• dough type matches product specification• dough temperature, consistency/texture, moisture

level, weight and colour• dough standing time• dough supply/quantities

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat related equipment is clean and correctly configuredfor processing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational. Setting selection may include:• setting parameters for process type• setting equipment speeds• adjusting roller and web settings (as required)• adjusting depositing/extrusion settings (as required)

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required toconfirm process remains within specification. This caninvolve monitoring:• biscuit size, shape and thickness• biscuit weight• dough temperature

• Form product to specification. This can involveconducting a trial run in preparation for production run




• Conduct product/batch changeovers• Locate emergency stop functions on equipment• Shut down equipment in response to an emergency


required to take process and related equipment off-line inpreparation for cleaning and/or maintenance within level




of responsibility• Complete workplace records as required• Maintain work area to meet housekeeping standards

May include ability to:• Use process control systems• Clean and sanitize equipment• Take samples and conduct tests• Carry out routine maintenance




Knowledge of: • Purpose and basic principles of biscuit forming• Basic operating principles of equipment. This may include

an operational understanding of main equipmentcomponents, status and purpose of guards, equipmentoperating capacities and applications, and the purposeand location of sensors and related feedbackinstrumentation. It also includes knowledge of servicesrequired and action to take if services are not available

• The flow of the biscuit forming process and the effect ofoutputs on downstream processes

• Effect of dough quality on process outcomes• Quality characteristics to be achieved by the process• Quality requirements of materials and effect of variation

on process performance• Operating requirements and parameters and corrective

action required where operation is outside specifiedoperating parameters. This includes procedures forincorporating rework dough and procedures for mendingwebs as required













and control• Routine maintenance procedures












parameters• Production schedule and recipe/batch instructions• Specifications, control points and processing parameters• Forming process and related equipment and services• Biscuit dough to be formed• Sampling and testing schedules and procedures, as

required• Sampling schedules and test procedures and equipment,


procedures• Cleaning procedures, materials and equipment, as

required





FDFBISRC2A Manufacture rye crisp breadsUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down the rye crisp breadsmanufacturing process.



1. Prepare the rye crispbreads manufacturingequipment and processfor operation







2. Operate and monitor therye crisp breadsmanufacturing process




2.4 The process is monitored to confirm that rye crisp breadsspecifications are met




3. Shut down the rye crispbreads manufacturingprocess





FDFBISRC2A Manufacture rye crisp breads


RANGE STATEMENT





• Equipment may include depositing, baking and cutting(revolving saws) and stacking equipment








EVIDENCE GUIDE


Ability to: • Access workplace information to identify rye crisp breadsmanufacturing requirements


• Confirm supply of necessary materials and services. Thisincludes confirming slurry quality, quantity, temperatureand degree of aeration

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat related equipment is clean and correctly configuredfor processing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational. Confirming settings may include:• ovens and cutter settings for product type• web speed settings• depositing rate settings• flour (dusting) process settings• docking roller adjusted for product type

• Start, operate, monitor and adjust rye crisp breadsmanufacturing equipment to achieve required outcomes.This may include monitoring control points andconducting inspections as required to confirm processremains within specification and ensuring that system hasreached specified temperature. This can involvemonitoring:• slurry volume, weight and density• biscuit size (width, length and thickness)• biscuit texture, colour and weight• biscuit moisture level• clean, even break/cut

• Monitor supply and flow of materials to and from the ryecrisp breads manufacturing process



responsibility• Locate emergency stop functions on equipment• Follow isolation and lock out/tag out procedures as

required to take the rye crisp breads manufacturingprocess and related equipment off-line in preparation forcleaning and/or maintenance within level of responsibility






• Use process control systems• Clean and sanitize equipment• Take samples and conduct tests• Conduct routine maintenance




Knowledge of: • Purpose and basic principles of each stage of the ryecrisp breads manufacturing process


• The flow of the rye crisp breads manufacturing processand the effect of outputs on downstream processes

• Quality characteristics to be achieved by the rye crispbreads manufacturing process

• Quality requirements of materials and effect of variationon process performance


• Effect of slurry temperature on its ability to hold air• Effect of docking roller on baking process• Changes which occur in product during processing• Typical equipment faults and related causes. This

includes recognition of signs and symptoms of faultyequipment and early warning signs of potential problems

• Methods used to monitor the rye crisp breadsmanufacturing process. This may include inspecting,measuring and testing as required by the process. Itrequires awareness of inspection or test points (controlpoints) in the process and the related procedures andrecording requirements

• Contamination/food safety risks associated with the ryecrisp breads manufacturing process and related controlmeasures




the rye crisp breads manufacturing process andworkplace production requirements. This includesemergency and routine shutdowns and procedures tofollow in the event of a power outage



• Environmental issues and controls relevant to the ryecrisp breads manufacturing process. This includeswaste/rework collection and handling procedures relatedto the process






• Sampling and testing associated with process monitoringand control









food safety and environmental requirements• Information on equipment capacity and operating

parameters• Production schedule and recipe/batch instructions• Depositing, baking, cutting, stacking and related

equipment and services• Specifications, control points and processing parameters• Dough/mix and slurry to meet production requirements• Sampling schedules and test procedures and equipment



required





FDFBISWP2A Manufacture wafer productsUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down the wafer productsmanufacturing process.



1. Prepare the wafer processfor operation







2. Operate and monitor thewafer process




2.4 The process is monitored to confirm that wafer productsmeet specifications




3. Shut down the waferprocess





FDFBISWP2A Manufacture wafer products


RANGE STATEMENT





• Equipment may include depositing and baking equipment,and wafer plates








EVIDENCE GUIDE


Ability to: • Access workplace information to identify wafer productionrequirements


• Confirm supply of necessary materials and services. Thisincludes confirming quality, quantity and temperature ofbatter

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat related equipment is clean and correctly configuredfor processing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational. This may include confirming:• correct batter is supplied• wafer plates are selected for product type• oven settings for product type• web/chain speed settings• depositing rate settings

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required toconfirm process remains within specification. This caninvolve monitoring:• wafer size (width, length and thickness)• wafer texture, colour and weight• wafer moisture level




responsibility• Locate emergency stop functions on equipment• Shut down equipment in response to an emergency


required to take process and related equipment offline inpreparation for cleaning and/or maintenance within levelof responsibility


May include ability to:• Use process control systems• Clean and sanitize equipment




• Take samples and conduct tests• Conduct routine maintenance




Knowledge of: • Purpose and basic principles of each stage of the wafermanufacturing process


• The flow of the wafer manufacturing process and theeffect of outputs on downstream processes

• Quality characteristics to be achieved by the wafermanufacturing process

• Quality requirements of materials and effect of variationon wafer manufacturing process performance

• Changes which occur in product during processing• Operating requirements and parameters and corrective



• Methods used to monitor the wafer manufacturingprocess. This may include inspecting, measuring andtesting as required by the process. It requires awarenessof inspection or test points (control points) in the processand the related procedures and recording requirements

• Contamination/food safety risks associated with the wafermanufacturing process and related control measures



the wafer manufacturing process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage




• Environmental issues and controls relevant to the wafermanufacturing process. This includes waste/reworkcollection and handling procedures related to the process







and control• Routine maintenance requirements and procedures









parameters• Production schedule and recipe/batch instructions• Depositing, baking and related equipment and services• Specifications, control points and processing parameters• Batter to be processed• Sampling schedules and test procedures and equipment



required





FDFCAKCSP2A Operate a cooling and slicing processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a process to cool and slice cake.This unit applies to the cutting of cake following baking on a band orbelt. It is not relevant for manual cutting of cake baked in a tin or pan.

Unit Sector Cake


1. Prepare the cooling andcutting equipment andprocess for operation

1.1 Baked cake is confirmed and available to meet productionrequirements

1.2 Cleaning and maintenance requirements and status isidentified and confirmed


1.4 Processing/operating parameters are selected as requiredto meet safety and production requirements



2. Operate and monitor thecooling and cuttingprocess




2.4 The process is monitored to confirm that cake temperatureand cut pieces meet specifications








FDFCAKCSP2A Operate a cooling and slicing process


RANGE STATEMENT





• Equipment typically includes conveyors, cooling tunnels,and rotary and guillotine knives



• Shut down procedures may include cleaning. In somecases cleaning may be carried out by a dedicatedcleaning crew

• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, and compressed and instrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify cooling andcutting requirements



knife condition to identify any signs of wear; selectingappropriate settings to meet cake dimensionrequirements; cancelling isolation or lockouts as required;confirming that equipment is clean and correctlyconfigured for processing requirements; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational. It may also includeconfirming:• conveyor speed• cooling tunnel settings• guides• knife position

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required toconfirm process remains within specification. This mayinclude monitoring:• cake temperature - temperature gauges• throughput• cut cake appearance, dimensions and weight• knife position and condition




• Demonstrate batch/product changeovers• Locate emergency stop functions on equipment• Follow isolation and lock out/tag out procedures as








Knowledge of: • Purpose and basic principles of the process• Basic operating principles of equipment. This may include


• Procedures to replace rotary knives• The flow of this process and the effect of outputs on

downstream processes• Outcomes to be achieved by the cooling and cutting

process. This includes an understanding of the requiredtemperature range for cake types and the scope to adjustproduct length to achieve a given weight

• Operating requirements and parameters and correctiveaction required where operation is outside specifiedoperating parameters. This includes an awareness of theeffect of ambient temperature on the cooling process, thepossible cause of condensation formation on productfrom the cooling tunnel, and corrective action required





• OHS hazards and controls. This includes awareness ofthe risks associated with working with refrigerant andaction required in the event of a leak

• Requirements of different shutdowns as appropriate tothe process and workplace production requirements. Thisincludes emergency and routine shutdowns andprocedures to follow in the event of a power outage






• Basic operating principles of process control whererelevant. This includes the relationship between control




panels and systems and the physical equipment• Routine maintenance procedures• Cleaning and sanitation procedures


Pre-requisite units



This unit should be assessed together with other units ofcompetence relevant to the work role. These may include:

• FDFZPRCI2A Operate a process control interface• FDFOPTCRM2A Conduct minor routine maintenance• FDFZCSCIP2A Clean equipment in place• FDFZCSCS2A Clean and sanitize equipment





parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Cooling tunnels, cutting equipment and related equipment

and services• Baked cake on a belt or band• Documentation and recording requirements and


required





FDFTCRG2B Manufacture coffee (roast and ground)Unit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a blending, roasting and grindingprocess.

Unit Sector Coffee


1. Prepare the blending,roasting and grindingprocess for operation







2. Operate and monitor theblending, roasting andgrinding process




2.4 Green beans are blended and roasted according toproduct and recipe specifications

2.5 Roasted beans are ground to product specifications2.6 Out-of-specification product/process outcomes are

identified, rectified and/or reported to maintain the processwithin specification



3. Shut down the roastingand grinding process





FDFTCRG2B Manufacture coffee (roast and ground)


RANGE STATEMENT





• Materials include varieties of green coffee beans, andprocess and packaging consumables

• Equipment may include roasters, grinding/milling system,blenders, transfer and storage systems, colour metersand destoners



• Services are appropriate to the process to be operated.Typical examples include power, steam, water, vacuum,and compressed and instrumentation air




EVIDENCE GUIDE





equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured forprocessing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational

• Start, operate, monitor and adjust the roasting processand equipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. This can involve monitoring:• temperatures• throughput/roasting times• product levels• water quench quantity• visually inspecting product - including bean colour

• Start, operate, monitor and adjust the grinding processand equipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. This can involve monitoring:• weight• density• product levels• particle size distribution











• Use process control systems• Conduct product/batch changeovers• Collect samples and conduct tests• Conduct routine maintenance• Clean and sanitise equipment




Knowledge of: • Steps and purpose of each stage in the roasting andgrinding process

• Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents, status and purpose of guards, basicprinciples and operation of roasting and grinding system,equipment operating capacities and applications, and thepurpose and location of sensors and related feedbackinstrumentation

• The flow of this process and the effect of product outputon downstream processes

• Quality characteristics to be achieved by the roasting andgrinding process

• Varieties of green beans and effect of beancharacteristics on roasting and grinding processes






• OHS hazards and controls. This includes awareness ofthe limitations of protective clothing and equipmentrelevant to the work process




• Environmental issues and controls relevant to theprocess. This includes waste collection and handlingprocedures related to the process










Pre-requisite units




• FDFZPRCI2A Operate a process control interface• FDFOPTISP2A Implement sampling procedures• PMLTEST300A Perform basic tests• FDFOPTSA2A Participate in sensory analysis• FDFOPTCRM2A Conduct routine maintenance• FDFZCSCS2A Clean and sanitize equipment




food safety, quality and environmental requirements• Production schedule and batch instructions• Specifications, control points and processing parameters• Information on equipment capacity and operating

parameters• Roasting and grinding process and related equipment

and services• Green beans• Sampling schedules and test procedures and equipment

as required• Cleaning procedures, materials and equipment as

required• Documentation and recording requirements and

procedures





FDFCONFBS2A Operate a boiled confectionery processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a high boil and low boilconfectionery process.

Unit Sector Confectionery


1. Prepare the high/low boilequipment and processfor operation


1.2 Ingredients for syrup are selected and combined in thesequence specified by batch/recipe instructions

1.3 Cleaning and maintenance requirements and status ofhigh/low boil process equipment are identified andconfirmed




2. Operate and monitor thehigh/low boil process

2.1 Ingredients and additives are delivered in the requiredquantities and sequence to meet recipe specifications




2.5 Product is heated, cooked and cooled according tospecification




3. Shut down the high/lowboil process





FDFCONFBS2A Operate a boiled confectionery process


RANGE STATEMENT





• Examples of high boil products include solid, striped andfilled confectionery

• Examples of low boil products may include caramels,nougats, creams, fudge, fondant, toffee, marshmallows,gums, jellies, licorice, paste, lozenges and fruit bars

• Product ingredients may include sugar substitutes• Typical equipment includes pan or vacuum cookers, cold

or marble tables and further processing equipmentdepending on use, such as forming, filling, pulling,beating, stamping, cooling equipment andcrystallising/beating equipment








EVIDENCE GUIDE


Ability to: • Access workplace information to identify high/low boilprocess requirements




• Start, operate, monitor and adjust high/low boil processequipment to achieve required outcomes. This includescombining ingredients in correct sequence according torecipe instructions; setting dosing/metering and relatedaddition systems; loading or controlling loading of bulkingredients; setting temperatures and operating vacuum;and may also include monitoring control points andconducting inspections as required to confirm processremains within specification. Monitoring may include:• mixing tank temperature• cooking temperatures• vacuum settings (where relevant)• moisture content• ingredient addition as required• product weight• appearance and organoleptic characteristics

• Monitor supply and flow of materials to and from thehigh/low boil process

• Demonstrate changeover procedures• Take corrective action in response to out-of-specification

results• Respond to and/or report equipment failure within level of


required to take high/low boil process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility



• Use process control systems• Collect samples and conduct tests




• Conduct routine maintenance• Clean and sanitize equipment




Knowledge of: • Purpose and basic principles of the high/low boil process.This relates to the range of products to be produced andmay include:• ingredients used and their purpose• syrup making (super saturated solutions)• relationship between temperature and moisture content• the effect of vacuum on processing• reactions such as crystallisation• process stages• maturation and further processing requirements

• Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents, status and purpose of guards, a basicunderstanding of the effect of vacuum on the cookingprocess and further processing, equipment operatingcapacities and applications, and the purpose and locationof sensors and related feedback instrumentation. It alsoincludes knowledge of services required and action totake if services are not available

• The flow of the high/low boil process and the effect ofoutputs on downstream processes

• Quality requirements of materials used in low/high boilmanufacture and effect of variation on processperformance and outputs

• Quality characteristics required of process outputs• Methods used to further process high and low boils. This

may include basic forming or extruding and stamping,cooling, pulling and aerating as required by product range



• Methods used to monitor the high/low boil process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the processand the related procedures and recording requirements

• Contamination/food safety risks associated with thehigh/low boil process and related control measures



the high/low boil process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage







• Environmental issues and controls relevant to thehigh/low boil process. This includes waste/reworkcollection and handling procedures related to the process




• Routine maintenance procedures• Cleaning and sanitizing procedures


Pre-requisite units




• FDFZPRCI2A Operate a process control interface• FDFOPTISP2A Implement sampling procedures• PMLTEST300A Perform basic tests• FDFOPTCRM2 A Conduct routine maintenance• FDFZCSCS2A Clean and sanitize equipment





parameters• Recipe/batch instructions• Specifications, control points and processing parameters• Process and related equipment and services, including

mixing equipment, cookers and coolers. It may alsoinclude further processing equipment as required

• Ingredients used in the preparation of high/low boilproduct as required

• Sampling schedules and test procedures and equipmentas required

• Documentation and recording requirements andprocedures

• Cleaning procedures, materials and equipment asrequired




FDFCONFCC2A Operate a chocolate conching processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a conching process.Unit Sector Confectionery


1. Prepare the conchingequipment and processfor operation

1.1 Refined mass is available to meet operating requirements1.2 Cleaning and maintenance requirements and status are

identified and confirmed1.3 Machine components and related attachments are fitted

and adjusted to meet operating requirements1.4 Processing/operating parameters are entered as required

to meet safety and production requirements1.5 Equipment performance is checked and adjusted as

required1.6 Pre-start checks are carried out as required by workplace

requirements

2. Operate and monitor theconching process

2.1 The conching process is started and operated accordingto workplace procedures



2.4 The process is monitored to confirm that specifications aremet




3. Shut down the conchingprocess

3.1 The appropriate shut own procedure is identified3.2 The process is shut down according to workplace




FDFCONFCC2A Operate a chocolate conching process


RANGE STATEMENT





• Conching and related equipment may include ingredientaddition equipment, continuous or batch conches andconveyor systems

• Processes may be batch or continuous. For batchprocesses, operators carry out changeovers withinworkplace arrangements and the relevant changeoverprocedures should be used to customise the details ofthis unit. Where more detailed changeovers are carriedout, also refer to FDFOPTCRM2A Conduct routinemaintenance



• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, steam, water, and compressed andinstrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify conchingprocess requirements


• Confirm supply of necessary refined mass and services• Conduct pre-start checks. This may involve inspecting

equipment condition to identify any signs of wear;selecting appropriate settings to achieve required particlesize; cancelling isolation or lockouts as required;confirming that equipment is clean and correctlyconfigured for processing requirements; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Load materials in required sequence and work flake tospecification

• Sequence ingredient addition to meet recipespecifications

• Monitor and adjust process equipment to achieverequired outcomes. This includes testing and adjustingviscosity and monitoring other control points as requiredto confirm process is within specification. Processmonitoring may include:• ingredient addition sequence• mix times• temperature• amperage/work input

• Monitor supply and flow of materials to and from theconche

• Demonstrate changeover procedures (unless continuousprocess)




required to take conching process and related equipmentoff-line in preparation for cleaning and/or maintenancewithin level of responsibility



• Use process control systems• Collect samples and conduct tests• Conduct routine maintenance• Clean and sanitize equipment




Knowledge of: • Purpose and basic principles of conching chocolate. Thisincludes:• processing stages in chocolate making and the role of

conching• ingredients used in chocolate and those added during

conching. This may include ingredients in differenttypes of chocolate as appropriate to productionrequirements and an understanding of the qualityrequirements and role of each main ingredient

• changes that occur in ingredients during conching• significance of viscosity and method/s of adjustment


• The flow of the conching process and the effect of outputson downstream processes

• Quality requirements of mass and ingredients used, andeffect of variation on process performance and outputs

• Quality characteristics required of the conching stage• Operating requirements and parameters and corrective



• Methods used to monitor the conching process. Thisincludes an understanding of viscosity testing proceduresand other inspections and tests as required. It requiresawareness of inspection or test points (control points) inthe process and the related procedures and recordingrequirements

• Contamination/food safety risks and related controlmeasures



the conching process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to theconching process. This includes waste/rework collection




and handling procedures related to the process






Pre-requisite units









parameters• Recipe/batch instructions• Specifications, control points and processing parameters• Conche and related equipment and services• Flake and ingredients for addition at the conching stage• Sampling schedules and test procedures and equipment



required





FDFCONFCP2A Operate a chocolate depositing/mouldingprocess

Unit Descriptor This is a Specialist unit. It covers the skills and knowledge required toset up, operate, adjust and shut down a depositing process thatdeposits chocolate into moulds or directly onto conveyors. This processis used to produce hollow, solid and filled chocolate products.



1. Prepare the depositingequipment and processfor operation


1.2 Equipment and ingredients are conditioned to meetproduction requirements





2. Operate and monitor thedepositing/mouldingprocess


2.2 Chocolate is deposited to achieve required coverage2.3 Equipment is monitored to identify variation in operating

conditions2.4 Variation in equipment operation is identified and

maintenance requirements are reported according toworkplace reporting requirements





3. Shut down thedepositing/mouldingprocess

3.1 The appropriate shut down procedure is identified3.2 The process is shut down according to workplace




FDFCONFCP2A Operate a chocolate depositing/moulding process


RANGE STATEMENT





• Ingredients may include chocolate and fillings or centers• Coverage of moulds can be achieved by vibrating,

spinning and/or inverting• Typical equipment includes pump, depositor head,

nozzle/injection plate, moulds, vibrators and shakers,cooling tunnel








EVIDENCE GUIDE


Ability to: • Access workplace information to identify chocolatedepositing process requirements



equipment condition to identify any signs of wear;selecting appropriate depositing head or settings;cancelling isolation or lockouts as required; confirmingthat equipment is clean; conditioning moulds/equipmentand ingredients to specified temperature; confirming thatdepositing head is correctly aligned; sensors and controlsare correctly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational

• Start, operate, monitor and adjust chocolate depositingprocess equipment to achieve required outcomes. Thismay include monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• maintaining supply of chocolate and centers to process

as required• temperatures of chocolate, moulds, depositor head,

injection plate and conveyor as required• pump stroke settings• temperature profile of cooling tunnel• deposited chocolate position/coverage• shrinkage/demoulding process as required• shell to filling weight ratio as required• appearance of deposited product

• Monitor supply and flow of materials to and from thechocolate depositing process and equipment operation toconfirm process remains within specification

• Demonstrate product/batch changeovers• Take corrective action in response to out-of-specification






• Use process control systems




• Collect samples and conduct tests• Carry out routine maintenance• Clean and sanitize equipment




Knowledge of: • Purpose and basic principles of the chocolate depositingprocess. This includes an understanding of theingredients used, handling and conditioning requirementsand process stages


• The flow of the chocolate depositing process and theeffect of outputs on downstream processes

• Quality characteristics and types of chocolate used fordepositing,

• Quality requirements of centers as appropriate to productand the effect of variation on process outputs

• Quality characteristics to be achieved by the depositedproduct



• Methods used to monitor the chocolate depositingprocess. This may include inspecting, measuring andtesting as required by the process. It requires awarenessof inspection or test points (control points) in the processand the related procedures and recording requirements

• Contamination/food safety risks associated with thechocolate depositing process and related controlmeasures



the chocolate depositing process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage




• Environmental issues and controls relevant to thechocolate depositing process. This includes waste/reworkcollection and handling procedures related to the process


• Basic operating principles of process control where








Pre-requisite units









parameters• Recipe/batch instructions• Specifications, control points and processing parameters• Process and related equipment and services• Chocolate and related ingredients such as fillings and

centers• Sampling schedules and test procedures and equipment



required





FDFCONFDP2A Operate a confectionery depositing processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required set

up, operate, adjust and shut down a depositing process to deposit intosolid or flexible moulds. This is sometimes known as starchlessmoulding.



1. Prepare the depositingequipment and processfor operation







1.7 Syrup is transferred to depositing equipment

2. Operate and monitor thedepositing process

2.1 The depositing process is started and operated accordingto workplace procedures



2.4 The depositing process is monitored to confirm thatspecifications are met




3. Shut down the depositingprocess





FDFCONFDP2A Operate a confectionery depositing process


RANGE STATEMENT





• Typical equipment includes a depositing hopper; nozzlesand manifold; moulds; finishing equipment such asblowing, oiling or sugaring; cooling tunnel. Relatedprocesses may include syrup preparation








EVIDENCE GUIDE


Ability to: • Access workplace information to identify depositingprocessing requirements



equipment condition to identify any signs of wear; andselecting appropriate settings and/or related parameters.This may include setting up depositor controls; coolingparameters and demoulding process to meet productionrequirements, and cancelling isolation or lockouts asrequired. Confirm that related equipment is clean andcorrectly configured for processing requirements; sensorsand controls are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Start, operate, monitor and adjust depositing processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• maintaining supply of syrup to hopper• controlling weight of liquid deposited in mould• visual inspections to identify faults such as tailings, and

placement of liquid in mould• pump stroke settings• cooling tunnel temperature profile• shrinkage/demoulding process

• Monitor supply and flow of materials to and from thedepositing process to confirm process remains withinspecification.

• Set up and operate finishing equipment as required• Demonstrate product changeover procedures• Take corrective action in response to out-of-specification



required to take depositing process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility







Knowledge of: • Purpose and basic principles of the depositing process.This may include product preparation and conditioningrequirements and product depositing


• The flow of the depositing process and the effect ofoutputs on downstream processes

• Quality requirements of materials for depositing and effectof variation on depositing process performance andoutputs

• Quality characteristics required of process outputs• Operating requirements and parameters and corrective



• Methods used to monitor the depositing process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the processand the related procedures and recording requirements

• Contamination/food safety risks associated with thedepositing process and related control measures



the depositing process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to thedepositing process. This includes waste/rework collectionand handling procedures related to the process









Pre-requisite units




• FDFZPRCI2A Operate a process control interface• FDFOPTISP2A Implement sampling procedures• PMLTEST300A Perform basic tests• FDFOPTCRM2A Conduct routine maintenance• FDFZCSCS2A Clean and sanitize equipment






conditioned moulds and depositing equipment• Ingredients/mix to be deposited• Sampling schedules and test procedures and equipment



required





FDFCONFGC2A Operate a granulation and compressionprocess

Unit Descriptor This is a Specialist unit. It covers the skills and knowledge required toset up, operate, adjust and shut down a granulation and compressionprocess.



1. Prepare the granulationequipment and processfor operation

1.1 Ingredients and additives are confirmed and available tomeet operating requirements


1.3 The granulation process is set to production specifications1.4 Equipment performance is checked and adjusted as


requirements

2. Prepare the compressionprocess for operation

2.1 Granulated materials are confirmed and available to meetoperating requirements

2.2 The compression process is set to productionspecifications



3. Operate and monitor thegranulation andcompression process


3.2 Ingredients are combined in specified sequence3.3 The granulation process is monitored to confirm granules

of the required particle size are produced3.4 The compression process produces compressed product

to specification3.5 Equipment is monitored to identify variation in operating






4. Shut down thecompression process





FDFCONFGC2A Operate a granulation and compression process


RANGE STATEMENT





• Granulation process may be wet or dry• Raw materials/ingredients which are added to the base

product, adhesives/binders, lubricants, fillers, colours andflavours

• Granulating equipment may include ribbon mixers,granulators, sieves, hammer mills and dryers

• Compressing equipment and accessories may includesingle or rotary punch compressors, punches and dies



• In-process tests may include appearance, hardness,friability, disintegration time, weight, dimensions






EVIDENCE GUIDE


Ability to: • Access workplace information to identify granulation andcompression process requirements




• Start, operate, monitor and adjust granulation processequipment to achieve required outcomes. This includespreparing granulated mix according to recipe instructionsand may also include monitoring control points andconducting inspections as required to confirm processremains within specification. Monitoring may include:• granule size• moisture content• fines

• Monitor supply and flow of materials to and from thegranulation process and equipment operation to confirmprocess remains within specification

• Start, operate, monitor and adjust compression processequipment to achieve required outcomes. This includesinstalling/setting punches and dies and may also includemonitoring control points and conducting inspections asrequired to confirm process remains within specification.Monitoring may include:• supply of materials• product appearance• product weight, thickness and hardness, friability. This

may require demonstration of related test procedures• Monitor supply and flow of materials to and from the

compression process to confirm process remains withinspecification.

• Demonstrate product/batch changeovers• Take corrective action in response to out-of-specification







Knowledge of: • Purpose and basic principles of the granulation andcompression process


• The flow of the granulation and compression process andthe effect of outputs on downstream processes

• Quality requirements of ingredients for granulating andeffect of variation on the granulation process

• Quality requirements of granulated mass and effect ofvariation on compression process

• Operating requirements of both granulation andcompression, related parameters and corrective actionrequired where operation is outside specified operatingparameters


• Methods used to monitor the granulation andcompression process. This may include inspecting,measuring and testing as required by the process. Itrequires awareness of inspection or test points (controlpoints) in the process and the related procedures andrecording requirements

• Contamination/food safety risks associated with thegranulation and compression process and related controlmeasures



the granulation and compression process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage




• Environmental issues and controls relevant to thegranulation and compression process. This includeswaste/rework collection and handling procedures relatedto the process






panels and systems and the physical equipment• Sampling and testing associated with process monitoring

and control• Routine maintenance procedures• Cleaning and sanitizing procedures


Pre-requisite units










granulation and compression equipment• Materials to be processed• Sampling schedules and test procedures and equipment



required





FDFCONFPP2A Operate a panning processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a panning process to coat tabletsand/or centers.



1. Prepare the panningequipment and processfor operation


1.2 Centers and coating are selected and prepared accordingto batch/recipe instructions


1.4 The panning process is prepared to meet safety andproduction requirements



2. Operate and monitor thepanning process








3. Shut down the panningprocess





FDFCONFPP2A Operate a panning process


RANGE STATEMENT





• Common applications of this process occur in theconfectionery and pharmaceutical industries

• Coatings may include hard and soft sugar or sugar-freesyrup and/or chocolate coating

• Where the panning operator is responsible for syruppreparation, refer to FDFCONFBS2A Operate a boiledconfectionery process

• Typical equipment includes coating pans, polishing pans,air blowing units and jacketed spray nozzles/heads




• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, steam, and compressed and instrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify panningprocessing requirements


• Confirm supply of necessary materials and services,including necessary centers and coating material (syrup,film or chocolate)

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured forprocessing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational

• Start, operate, monitor and adjust panning processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• pan preparation/coating• coating addition rate• sieving• colour addition• drying air temperature and flow• addition of polishing agent/gum

• Monitor supply and flow of materials to and from thepanning process to confirm process remains withinspecification


• Follow workplace procedures for reworking scrap orout-of-specification product

• Demonstrate product/batch changeovers• Respond to and/or report equipment failure within level of









• Carry out routine maintenance• Clean and sanitize equipment




Knowledge of: • Purpose and basic principles of the panning process. Thismay include an understanding of centerpreparation/conditioning procedures and requirements,coating preparation and the stages in the panningprocess


• The flow of the panning process and the effect of outputson downstream processes

• Conditioning requirements for centers and coatings• Quality characteristics of centers and coatings for use in

the panning process and the effect of variation onpanning process performance and outputs

• Quality characteristics to be achieved by the process• Operating requirements and parameters and corrective



• Methods used to monitor the panning process. This mayinclude inspecting, measuring and testing as required bythe process. It requires awareness of inspection or testpoints (control points) in the process and the relatedprocedures and recording requirements

• Food safety/contamination risks associated with theprocess and related control measures



the panning process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to thepanning process. This includes waste/rework collectionand handling procedures related to the process







and control• Routine maintenance procedures• Cleaning and sanitizing procedures


Pre-requisite units









parameters• Recipe/batch instructions• Specifications, control points and processing parameters• Process and related equipment and services• Materials to be processed, including centers and coating

ingredients• Sampling schedules and test procedures and equipment



required





FDFCONFRC2A Operate a chocolate refining processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a chocolate mixing and refiningprocess.



1. Prepare and mixingredients

1.1 Ingredients are confirmed and available to meet operatingrequirements

1.2 Mixing processing/operating parameters are entered asrequired to meet safety and production requirements

1.3 Ingredients and additives are delivered to the mixer in therequired quantities and sequence to meet recipespecifications

1.4 The mixing process is started and operated according toworkplace procedures



1.7 The mixing process is monitored to confirm thatspecifications are met


2. Prepare the refiningequipment and processfor operation

2.1 Mix is available to meet operating requirements2.2 Cleaning and maintenance requirements and status are


and adjusted to meet operating requirements2.4 Processing/operating parameters are entered as required

to meet production requirements2.5 Equipment performance is checked and adjusted as


requirements


FDFCONFRC2A Operate a chocolate refining process


3. Operate and monitor therefining process

3.1 The refining process is started and operated according toworkplace procedures







4. Shut down the refiningprocess







RANGE STATEMENT





• Refining and related equipment may include bulkmaterials handling equipment, continuous or batchmixers/kneaders, pre-refiners and refiners, conveyorsystems








EVIDENCE GUIDE


Ability to: • Access workplace information to identify mixing andrefining process requirements


• Confirm supply of necessary ingredients and services• Conduct pre-start checks. This may involve inspecting

equipment condition to identify any signs of wear;selecting appropriate settings to achieve required particlesize; cancelling isolation or lockouts as required;confirming that equipment is clean and correctlyconfigured for processing requirements; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Sequence ingredient addition to the mixer to meet recipespecifications

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This includes combiningingredients in correct sequence according to recipeinstruction; setting dosing/metering and related additionsystems; loading or controlling loading of bulk ingredients;and may also include monitoring control points andconducting inspections as required to confirm processremains within specification. Monitoring may include:• ingredient addition sequence• mix times• throughput to refiner• roller gap/particle size

• Monitor supply and flow of materials to and from themixing and refining

• Demonstrate changeover procedures• Take corrective action in response to out-of-specification



required to take refining process and related equipmentoff-line in preparation for cleaning and/or maintenancewithin level of responsibility







Knowledge of: • Purpose and basic principles of mixing and refiningchocolate. This includes:• processing stages in chocolate making and the role of

mixing, refining and pre-refining as appropriate• ingredients used in chocolate and those introduced

during refining. This may include ingredients indifferent types of chocolate as appropriate toproduction requirements and an understanding of thequality requirements and role of each main ingredient

• changes that occur in ingredients during mixing andrefining

• significance of particle size for product characteristics• Basic operating principles of equipment. This may include


• The flow of the mixing and refining process and the effectof outputs on downstream processes

• Quality requirements of ingredients used and effect ofvariation on process performance and outputs

• Quality characteristics required of the refined mass• Operating requirements and parameters and corrective



• Methods used to monitor the mixing and refining process.This may include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the processand the related procedures and recording requirements




the mixing and refining process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to the mixingand refining process. This includes waste/rework




collection and handling procedures related to the process






Pre-requisite units










mixing equipment and refiner. It may also includepre-refining equipment as required

• Ingredients for inclusion in the mixing/refining stage• Sampling schedules and test procedures and equipment



required





FDFCONFSM2A Operate a starch moulding processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down sugar moulded products using astarch moulding process.



1. Prepare the starchmoulding equipment andprocess for operation


1.2 Starch is correctly conditioned for moulding1.3 Cleaning and maintenance requirements and status are

identified and confirmed1.4 Starch mould is prepared to meet production requirements1.5 Processing/operating parameters are selected for the

depositor, starch moulding and starch removal equipmentto meet safety and production requirements

1.6 Ingredients/mix is transferred to depositing equipment1.7 Equipment performance is checked and adjusted as


requirements

2. Operate and monitor thestarch moulding andremoval process








3. Shut down the starchmoulding process





FDFCONFSM2A Operate a starch moulding process


RANGE STATEMENT





• Typical starch moulded products include gums and jellies,marshmallows, caramels

• Materials may include starch and low or high boil syrups• Typical equipment includes boiling pans (batch), moguls

(continuous process), drying room and starch cleaningequipment. Related processes may include mixing andcooking of ingredients prior to depositing








EVIDENCE GUIDE


Ability to: • Access workplace information to identify starch mouldingprocessing requirements


• Confirm supply of necessary materials and services. Thisincludes confirming starch condition and mould type

• Prepare product for depositing. This may includeingredient addition, mixing and cooking to specification

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured forprocessing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational. Setup may include setting up depositorcontrols, controls for depositing and stamping starchmoulds, destarching and finishing equipment

• Deposit and stamp starch moulds• Set up destarching and finishing equipment. This may

include blowing, oiling or sugaring clean starch and dryingstarch for re-use

• Start, operate, monitor and adjust starch mouldingprocess equipment to achieve required outcomes. Thismay include monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• maintaining supply of liquid mass to hopper• controlling weight of liquid deposited in mould• monitoring pump stroke settings• visual inspections to identify faults such as tailings and

placement of liquid in mould• Monitor supply and flow of materials to and from the

starch moulding process and equipment operation toconfirm process remains within specification

• Demonstrate depositor head changeovers• Take corrective action in response to out-of-specification








Knowledge of: • Purpose and basic principles of the starch mouldingprocess. This includes an understanding of each stage:• starch mould preparation• product preparation and conditioning• product depositing• starch use and recovery cycle


• The flow of the starch moulding and depositing processand the effect of outputs on downstream processes

• Quality requirements of starch moulds and materials fordepositing and effect of variation on starch mouldingprocess performance and outputs. This includes themoisture absorption characteristics of starch and impacton the process

• Quality characteristics required of process outputs• Operating requirements and parameters and corrective



• Methods used to monitor the starch moulding process.This may include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the processand the related procedures and recording requirements

• Contamination/food safety risks associated with thestarch moulding process and related control measures



the starch moulding process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to the starchmoulding process. This includes waste/rework collectionand handling procedures related to the process









Pre-requisite units










moulds, starch stamping and mould preparation anddepositing equipment

• Materials to be processed, including starch for mouldingand ingredients/mix to be deposited


• Documentation and recording requirements andprocedures






FDFDPBC2B Operate a butter churning processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a butter churning process toproduce sweet cream butter product to specifications.

Unit Sector Dairy Processing


1. Prepare the butterchurning equipment andprocess for operation







2. Operate and monitor thebutter churning process








3. Shut down the butterchurning process





FDFDPBC2B Operate a butter churning process


RANGE STATEMENT





• Butter churning equipment may include butter churn,augers, separator, salter, and vacuum

• Materials used in butter churning may include pasteurisedcream, and salt. By-products may include buttermilk andwash water








EVIDENCE GUIDE


Ability to: • Access workplace information to identify requirements forthe butter churning process




• Start, operate, monitor and adjust butter churning processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. This may include monitoring:• agitation speeds• flow rates• time/temperature• ingredient addition systems• equipment performance

• Monitor supply and flow of materials to and from thebutter churning process




required to take butter churning process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility



• Use process control systems• Collect samples and conduct tests• Clean equipment• Conduct routine maintenance• Carry out product/batch changeovers




Knowledge of: • Purpose and basic principles of the butter churningprocess. This includes an understanding of the principlesof product preservation and the types ofadditives/ingredients used in the process

• Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents, status and purpose of guards, equipmentoperating capacities and applications, and the purposeand location of sensors and related feedbackinstrumentation

• The flow of the butter churning process and the effect ofproduct output on downstream processes

• Quality characteristics to be achieved by the butterchurning process


• The effect of raw material characteristics on the butterchurning process



• Techniques used to monitor the butter churning process.This may include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the processand the related procedures and recording requirements










• Cleaning and sanitation procedures• Routine maintenance procedures• Product/batch changeover procedures





Pre-requisite units








food safety, quality and environmental requirements,stock flow systems, production schedules, batch/recipeinstructions

• Information on equipment capacity and operatingparameters

• Production schedule and batch instructions• Butter churning process and related equipment and

services• Specifications, control points and processing parameters• Materials required for the butter churning process• Sampling schedules and test procedures and equipment

as required• Routine preventative maintenance schedule as required• Documentation and recording requirements and


required





FDFDPBF2B Operate a continuous freezing processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, monitor and shut down a continuous freezing processtypically used to manufacture ice cream, ice confection and/or ice milkproducts. This unit may apply to both batch and continuous freezingprocesses.



1. Prepare the freezingequipment and processfor operation







2. Monitor the freezingprocess operation








3. Shut down the freezingprocess





FDFDPBF2B Operate a continuous freezing process


RANGE STATEMENT





• Freezing and related equipment may include in-lineextruders, dashers, churns, pumps, fruit feeder, andhardening rooms/tunnels/machines

• Materials used in freezing may include fat, milk solids notfat, sugars, emulsifiers, stabilisers, water, flavours, colour,and bulking agents








EVIDENCE GUIDE






• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required toconfirm process remains within specification. This mayinclude monitoring:• flow rates• churn speed• time/temperature• ingredient addition systems• pressures• equipment condition and performance








• Use process control systems• Demonstrate batch/product changeovers (may not apply

to some continuous operations)• Collect samples and conduct tests• Conduct routine maintenance• Clean and sanitize equipment




Knowledge of: • Purpose and basic principles of the process. Thisincludes an understanding of the stages that occur duringthe churning and freezing process and the requiredphysical and microstructure of the product



• Additives and ingredients used and their role in theproduct

• Quality characteristics to be achieved by the freezingprocess

• Quality requirements of materials/ingredients and effect ofvariation on process performance


















• Routine maintenance procedures• Cleaning procedures


Pre-requisite units









parameters• Production schedules and batch instructions• Specifications, control points and processing parameters• Freezing process and related equipment and services• Materials/ingredients to be processed• Sampling schedules and test procedures and equipment



required





FDFDPBOP2A Operate a butter oil processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, monitor and shut down the components of a butter oilprocess. This process is also known as an anhydrous milk fat (AMF)process. This process is used for the preparation of butter oil fromeither cream or melted butter.



1. Prepare the butter oilequipment and processfor operation






2. Monitor the butter oilprocess operation




2.4 Each stage of the process is monitored to confirm thatspecifications are met




3. Shut down the butter oilprocess





FDFDPBOP2A Operate a butter oil process


RANGE STATEMENT





• Products produced using this process include AnhydrousMilk Fat (AMF), Anhydrous Butteroil and Butteroil. Phaseinversion produces butter milk which is typicallyevaporated and dried. This unit does not cover thisactivity.

• When producing butteroil from cream, typical equipmentused for phase inversion includes heat exchangers,centrifugal separators and homogenisers. Phaseinversion when using butter requires use of a buttermaker/churn. Post phase inversion equipment mayinclude separators, dehydrators (vacuum vessel), holdingand balance tanks and heat exchangers

• Typical stages include concentration, phase inversion(using an homogeniser when working direct from creamand a melting and holding stage if using butter), finalconcentration, neutralisation, polishing and dehydration.Fractionation and decholesterolisation may also becarried out








EVIDENCE GUIDE




• Confirm supply of necessary materials and services. Thismay include confirming that characteristics of infeed(cream or butter) meet quality requirements

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat equipment is clean, correctly configured forprocessing requirements, sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required toconfirm process remains within specification.• For the phase inversion stage, this typically includes

monitoring colour• For the oil concentration stage, this typically includes

monitoring oil transparency. In a direct from creamprocess, it may involve checking homogeniser andcentrifuge pressures, centrifuge operation anddesludging. For a butter process, the centrifugalseparator pressures, and desludging and heatexchanger temperatures are also monitored

• For the neutralisation stage, this typically includesmonitoring water flow and temperatures, pH andcaustic concentration

• For the polishing stage, this typically includesmonitoring water temperatures and productappearance - clarity

• For the dehydration stage, this typically includesmonitoring operation of the centrifuge to flash offremaining moisture in oil









Knowledge of: • Purpose and basic principles of each stage in theprocess. This includes an understanding of the stages,process flow and phases produced

• Basic operating principles of equipment. This includes anunderstanding of the principles of centrifuges and a basicunderstanding of the principles of evaporation It may alsoinclude an operational understanding of main equipmentcomponents, status and purpose of guards; equipmentoperating capacities and applications and the purposeand location of sensors and related feedbackinstrumentation; together with a knowledge of servicesrequired and action to take if services are not available

• The effect of outputs on downstream processes• Quality characteristics (fat content) to be achieved by the

process• Quality requirements of infeed materials (cream or butter)

and the effect of variation in material quality on processperformance





• Common causes of variation and corrective actionrequired. For example, the ability to identify how earlierstages in the process could contribute to cloudy product















Pre-requisite units

The pre-requisite units for this competency are as follows.

For a direct from cream process:

• FDFZPROH2A Operate an homogenisation process

For a butter process:

• FDFDPBC2B Operate a butter churning process








parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Butter oil and related equipment and services• Cream or butter to be processed• Sampling schedules and test procedures and equipment



required





FDFDPCC2B Operate a curd production and cuttingprocess

Unit Descriptor This is a Specialist unit. It covers the skills and knowledge required toset up, operate, adjust and shut down a curd production and cuttingprocess in cheesemaking.



1. Prepare the curdproduction and cuttingprocess for operation







2. Operate and monitor thecurd production andcutting process








3. Shut down the curdproduction and cuttingprocess





FDFDPCC2B Operate a curd production and cutting process


RANGE STATEMENT





• Curd production and cutting equipment will depend on thetype of cheese products and may include vats

• Materials used in curd production may include milk andcoagulants








EVIDENCE GUIDE


Ability to: • Access workplace information to identify curd productionand cutting process requirements




• Start, operate, monitor and adjust curd production andcutting process equipment to achieve required outcomes.This may include monitoring control points andconducting inspections as required to confirm processremains within specification. This may include monitoring:• speeds• flow rates• time/temperature• equipment performance

• Monitor supply and flow of materials to and from the curdproduction and cutting process


• Conduct product/batch changeover• Respond to and/or report equipment failure within level of


required to take curd production and cutting process andrelated equipment off-line in preparation for cleaningand/or maintenance within level of responsibility

• Prepare curd production and cutting equipment forcleaning







Knowledge of: • Purpose and basic principles of the curd production andcutting process. This includes an understanding of themethods used to coagulate milk for cheesemaking


• The flow of this curd production and cutting process andthe effect of product output on downstream processes

• Stages and changes that occur during curd production.This includes an understanding of the physical andchemical changes that occur during curd production andcutting

• Quality characteristics required for curd production andcutting

• Factors that affect curd firmness• Contamination/food safety risks associated with the

process and related control measures• The effect of raw material characteristics on curd

production and cutting• Operating requirements and parameters and corrective



• Techniques used to monitor the curd production andcutting process. This may include inspecting, measuringand testing as required by the process. It requiresawareness of inspection or test points (control points) inthe process and the related procedures and recordingrequirements



• Requirements of different shutdowns as appropriate tothe curd production and cutting process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage



• Environmental issues and controls relevant to the curdproduction and cutting process. This includes wastecollection and handling procedures related to the process









Pre-requisite units










• Production schedule and recipe/batch instructions• Curd production and cutting process and related

equipment and services• Specifications, control points and processing parameters• Materials required for a curd production and cutting

process• Sampling schedules and test procedures and equipment



required





FDFDPCH2B Operate a cooling and hardening processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a process to cool and hardendairy products to specification.



1. Prepare the cooling/hardening process foroperation







2. Operate and monitor thecooling/ hardeningprocess








3. Shut down thecooling/hardening process





FDFDPCH2B Operate a cooling and hardening process


RANGE STATEMENT





• Cooling/hardening equipment may include hardeningtunnel, plate hardening machine, jacket holding tank,refrigeration, and cooling towers








EVIDENCE GUIDE


Ability to: • Access workplace information to identifycooling/hardening processing requirements




• Start, operate, monitor and adjust cooling/hardeningprocess equipment to achieve required outcomes. Thismay include monitoring control points and conductinginspections as required to confirm process remains withinspecification. This may include monitoring:• time/temperature• flow rates• recording devices/gauges• pressure• coolant circulation• equipment performance

• Monitor supply and flow of materials to and from thecooling/hardening process




required to take cooling/hardening process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility

• Prepare cooling/hardening equipment for cleaning• Complete workplace records as required• Maintain work area to meet housekeeping standards


• Use process control systems• Collect samples and conduct tests• Clean and sanitize equipment• Conduct routine maintenance• Conduct product/batch changeover




Knowledge of: • Purpose and basic principles of the cooling/hardeningprocess. This includes an understanding of principles ofheat transfer and the difference between latent heatenergy transfer and sensible heat energy transfer


• The flow of the cooling/hardening process and the effectof product output on downstream processes

• Stages and changes which occur duringcooling/hardening

• Quality characteristics to be achieved bycooling/hardening process

• Effect of infeed characteristics on cooling/hardeningprocess performance



• Techniques used to monitor the cooling/hardeningprocess. This may include inspecting, measuring andtesting as required by the process. It requires awarenessof inspection or test points (control points) in the processand the related procedures and recording requirements







• Environmental issues and controls relevant to thecooling/hardening process. This includes waste collectionand handling procedures related to the process




• Cleaning and sanitation procedures




• Routine maintenance procedures• Product/batch changeover procedures


Pre-requisite units










• Production schedule and batch instructions• Cooling/hardening process and related equipment and

services• Specifications, control points and processing parameters• Materials required for a cooling/hardening process• Sampling schedules and test procedures and equipment



required





FDFDPCM2B Operate a cheese pressing and mouldingprocess

Unit Descriptor This is a Specialist unit. It covers the skills and knowledge required toset up, operate, adjust and shut down a pressing and moulding processto produce cheese to specifications.



1. Prepare the pressing andmoulding equipment andprocess for operation







2. Operate and monitor thepressing and mouldingprocess








3. Shut down the pressingand moulding process





FDFDPCM2B Operate a cheese pressing and moulding process


RANGE STATEMENT





• Cheese pressing and moulding equipment may includeblock forming towers, trolley table, tunnel press,pneumatic press, hydraulic press, screw press, andmoulds,

• Materials used in cheese pressing and moulding mayinclude curd, salt,








EVIDENCE GUIDE


Ability to: • Access workplace information to identify pressing andmoulding processing requirements



equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured forpressing and moulding processing requirements; sensorsand controls are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Start, operate, monitor and adjust pressing and mouldingprocess equipment to achieve required outcomes. Thismay include monitoring control points and conductinginspections as required to confirm process remains withinspecification. This may include monitoring:• equipment speeds• flow rates• time/temperature• equipment performance

• Monitor supply and flow of materials to and from thepressing and moulding process




required to take pressing and moulding process andrelated equipment off-line in preparation for cleaningand/or maintenance within level of responsibility



• Use process control systems• Collect samples and conduct tests• Conduct product/batch changeovers• Conduct routine maintenance• Clean equipment




Knowledge of: • Purpose and basic principles of the pressing andmoulding process

• Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents, equipment status and purpose of guards,operating capacities and applications, and the purposeand location of sensors and related feedbackinstrumentation

• The flow of the pressing and moulding process and theeffect of product output on downstream processes

• Quality characteristics to be achieved by the pressing andmoulding process

• Effect of raw material characteristics on pressing andmoulding process performance




• Techniques used to monitor the pressing and mouldingprocess. This may include inspecting, measuring andtesting as required by the process. It requires awarenessof inspection or test points (control points) in the processand the related procedures and recording requirements










• Product/batch changeover procedures• Routine maintenance procedures• Cleaning and sanitation procedures





Pre-requisite units










• Production schedules and batch instructions• Pressing and moulding process and related equipment

and services• Specifications, control points and processing parameters• Materials required for a pressing and moulding process• Sampling schedules and test procedures and equipment



required





FDFDPFP2B Operate a fermentation processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a fermentation process typicallyused in the production of dairy products.



1. Prepare the fermentationequipment and processfor operation







2. Monitor the fermentationprocess operation








3. Shut down thefermentation process





FDFDPFP2B Operate a fermentation process


RANGE STATEMENT





• Fermentation equipment may include water baths,cabinets, tunnels, multipurpose tanks, and fermentationtanks

• Materials used in fermentation may include rawmaterials/pre-processed materials to be fermented,starters such as single strain starters, multiple straincultures, and mixed strains








EVIDENCE GUIDE





equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters,cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured forprocessing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational

• Start, operate, monitor and adjust fermentation equipmentto achieve required outcomes. This may includemonitoring control points and conducting inspections asrequired to confirm process remains within specification.This may include monitoring:• time/temperature• flow rates• fermenter speeds• equipment condition and performance













Knowledge of: • Purpose and basic principles of the fermentation process.This includes an understanding of the stages andreactions that occur during fermentation



• Quality characteristics to be achieved by the fermentationprocess

• Types of starters used and their role in the fermentationprocess




• Methods used to monitor the fermentation process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the processand the related procedures and recording requirements










• Product/process changeover procedures and




responsibilities• Sampling and testing associated with process monitoring

and control• Routine maintenance procedures• Cleaning procedures


Pre-requisite units









parameters• Production schedules and batch instructions• Specifications, control points and processing parameters• Fermentation and related equipment and services• Materials to be fermented• Sampling schedules and test procedures and equipment



required





FDFDPHS2B Operate a holding and storage processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a holding/storage process underconditions that control the quality of the product. This process mayapply to raw milk and/or processed products.



1. Prepare the holding andstorage equipment andprocess for operation







2. Operate and monitor theholding and storageprocess








3. Shut down the holdingand storage process





FDFDPHS2B Operate a holding and storage process


RANGE STATEMENT





• Holding/storage equipment may include silos,intermediate storage tanks, aseptic storage tanks,mixing/blending tanks, process tanks, balance tanks




• Services are appropriate to the holding and storageprocess to be operated. Typical examples include power,steam, water, vacuum, and compressed andinstrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify requirements forthe holding and storage process


• Confirm supply of necessary materials and services forthe holding and storage process


• Start, operate, monitor and adjust holding and storageprocess equipment to achieve required outcomes. Thismay include monitoring control points and conductinginspections as required to confirm process remains withinspecification. This may include monitoring:• time/temperature• flow rates• agitation speed• equipment condition and performance

• Monitor supply and flow of materials to and from theholding and storage process




required to take holding and storage process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility



• Use process control systems• Collect samples and conduct tests• Conduct routine maintenance• Clean equipment




Knowledge of: • Purpose and basic principles of the holding/storageprocess including the importance of stock rotation


• The flow of the holding and storage process and theeffect of product output on downstream processes


• Quality characteristics to be achieved by the holding andstorage process. This may include an understanding oforganoleptic characteristics of the product

• Effect of raw material characteristics on the holding andstorage process



• Techniques used to monitor the holding and storageprocess. This may include inspecting, measuring andtesting as required by the process. It requires awarenessof inspection or test points (control points) in the processand the related procedures and recording requirements



• Requirements of different shutdowns as appropriate tothe holding and storage process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage







• Routine maintenance procedures






Pre-requisite units









• Specifications, control points and processing parameters• Information on equipment capacity and operating

parameters• Production schedule and batch instructions• Holding and storage process and related equipment and

services• Materials required for a holding/storage process• Sampling schedules and test procedures and equipment



required





FDFDPMP2B Operate a membrane processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a membrane process used toseparate the components of solutions and suspensions.



1. Prepare the membraneequipment and processfor operation







2. Operate and monitor themembrane process








3. Shut down the membraneprocess

3.1 The appropriate shutdown and cleaning procedure isidentified

3.2 The process is shut down according to workplaceprocedures

3.3 Maintenance requirements are identified and reportedaccording to workplace reporting requirements


FDFDPMP2B Operate a membrane process


RANGE STATEMENT





• Membrane modules may be flat sheet (plate), spirallywound, hollow fibre, or tubular and may have asymmetrical, asymmetric or composite asymmetricstructure. Related equipment typically includes pipework,valves and pumps, and refrigeration equipment








EVIDENCE GUIDE


Ability to: • Access workplace information to identify membraneprocessing requirements



equipment/membrane condition to identify any signs ofwear; selecting appropriate settings and/or relatedparameters; cancelling isolation or lockouts as required;confirming that equipment such as pumps, valves andpipework are clean and correctly configured formembrane processing requirements; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Start, operate, monitor and adjust membrane processingequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. This may include monitoring:• temperatures• flow rates• total solids• pressure/vacuum

• Monitor supply and flow of materials to and from themembrane process

• Conduct run/batch changeovers• Take corrective action in response to out-of-specification



required to take membrane processing and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility

• Follow procedures to clean membranes• Complete workplace records as required• Maintain work area to meet housekeeping standards


• Use process control systems• Conduct routine maintenance• Collect samples and conduct tests




Knowledge of: • Purpose and basic principles of membrane processing.This includes an understanding of the components ofmilk, particle size of each component and the effect onthese components of membrane processing. It alsoincludes an understanding of the methods used toachieve this outcome

• Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents, status and purpose of guards, equipmentoperating capacities and applications, and the purposeand location of sensors and related feedbackinstrumentation. It also includes an awareness of thematerial composition of membranes used in theworkplace and related operating, cleaning and storagerequirements

• The flow of the membrane process including the differentprocessing streams and the effect of the membraneprocess outputs on downstream processes

• Quality characteristics required of the membraneprocessing outputs

• The effect of variation in raw material characteristics onmembrane processing performance

• Operating requirements and parameters and correctiveaction required where operation is outside specifiedoperating parameters. This includes an understanding ofthe effect of variation in processing parameters such astemperature, pressure, total solids and flow rates onmembrane process performance


• Techniques used to monitor membrane processing. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the processand the related procedures and recording requirements




• Requirements of different shutdowns as appropriate tomembrane processing and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage and shutdown

• Cleaning and sanitation requirements associated withchangeovers


• Procedures and responsibility for reporting production




and performance information• Environmental issues and controls relevant to membrane

processing. This includes waste collection and handlingprocedures related to the process



• Routine maintenance procedures• Sampling and testing associated with process monitoring

and control


Pre-requisite units










• Production schedule and batch instructions• Specifications, control points and processing parameters• Membrane processing and related equipment and

services• Materials required for membrane processing• Sampling schedules and test procedures and equipment


procedures• Cleaning and sanitation procedures, materials and

equipment as required




FDFEOBP2B Operate a bleaching processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a bleaching process to removecolour and impurities from partially refined oil.

Unit Sector Edible Oils & Fats


1. Prepare the bleachingequipment and processfor operation







2. Operate and monitor thebleaching process




2.4 The process is monitored to confirm that bleached oilmeets colour specifications




3. Shut down the bleachingprocess





FDFEOBP2B Operate a bleaching process


RANGE STATEMENT



• Legislative requirements are typically reflected inprocedures and specifications. Legislation relevant to thisindustry includes the Food Standards Code includinglabelling, weights and measures legislation, andlegislation covering food safety, environmentalmanagement, occupational health and safety,anti-discrimination and equal opportunity


• Bleaching equipment may include holding/storage tanks,bleaching vessel, pump, heat exchanger, filter system

• Materials used in bleaching may include neutralised oil,bleaching earth, filter aid, filter cloths, papers and bags

• Processes may be batch or continuous and apply tosingle or multiple product types








EVIDENCE GUIDE


Ability to: • Access workplace information to identify bleachingprocess requirements


• Confirm supply of necessary oil, materials and services• Conduct pre-start checks. This may involve inspecting

equipment condition to identify any signs of wear;confirming availability of tank space; selecting appropriatesettings and/or related parameters; cancelling isolation orlockouts as required; confirming that equipment is cleanand correctly configured for bleaching processrequirements; sensors and controls are correctlypositioned; any scheduled maintenance has been carriedout, and that all safety guards are in place andoperational

• Start, operate, monitor and adjust bleaching processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• time/temperature• contact time and agitation• air contact• product quality

• Monitor supply and flow of materials to and from thebleaching process




required to take bleaching process and related equipmentoff-line in preparation for cleaning and/or maintenancewithin level of responsibility

• Demonstrate batch/product changeovers as required• Complete workplace records as required• Maintain work area to meet housekeeping standards






Knowledge of: • Purpose and basic principles of the bleaching process• Basic operating principles of equipment. This may include


• The flow of the bleaching process and the effect ofoutputs on downstream processes

• Quality characteristics to be achieved by the bleachingprocess

• Quality requirements of materials and effect of variation inoil quality on bleaching process performance



• Methods used to monitor the bleaching process. This mayinclude inspecting, measuring and testing as required bythe process. It requires awareness of inspection or testpoints (control points) in the bleaching process and therelated procedures and recording requirements

• Contamination/food safety risks associated with thebleaching process and related control measures



• Requirements of different shutdowns as appropriate tothe bleaching process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to thebleaching process. This includes waste/rework collectionand handling procedures related to the process



• Sampling and testing associated with bleaching processmonitoring and control






Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Bleaching process and related equipment and services• Oil, catalyst and filter aid as required by the bleaching

process used• Sampling schedules and test procedures and equipment



required





FDFEOCP2A Operate a complecting processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a complector used to producepastry margarine.



1. Prepare the complectorand related equipment foroperation

1.1 Oil stock and emulsion are available to meet operatingrequirements






2. Operate and monitor thecomplector process

2.1 The complector is started and operated according toworkplace procedures











FDFEOCP2A Operate a complecting process


RANGE STATEMENT




• Workplace information may include Standard OperatingProcedures (SOPs), specifications/recipes, productionschedules and instructions, manufacturers' advice,standard forms and reports

• Equipment may include tanks and hoppers, complectorand packing equipment




• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, steam, vacuum, water, and compressed andinstrumentation air




EVIDENCE GUIDE




• Confirm supply of flake for further processing• Conduct pre-start checks on complector and related

equipment. This may involve inspecting equipmentcondition to identify any signs of wear; selectingappropriate settings and/or related parameters; cancellingisolation or lockouts as required; confirming thatequipment is clean and correctly configured forprocessing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required toconfirm process remains within specification. This mayinclude monitoring:• temperatures• work input• rest times• tepid water temperatures• throughput• vacuum• packing speed



• Demonstrate batch/product changeovers• Respond to and/or report equipment failure within level of





• Use process control systems• Collect samples and conduct tests. This may include

organoleptic tests• Package finished pastry margarine• Conduct routine maintenance




• Clean and sanitize equipment




Knowledge of: • Principles of preparing pastry margarine using acomplector. This includes a basic understanding ofcrystallisation; the relationship between stages of crystalformation, work input and temperature; and the purposeand requirements of a holding stage



• Quality characteristics to be achieved by the final pastrymargarine. This will vary according to types of pastrymargarine produced

• Quality requirements of flake used and effect of variationon process performance






• OHS hazards and controls• Product/process changeover procedures and

responsibilities• Requirements of different shutdowns as appropriate to




• Environmental issues and controls relevant to theprocess. This includes waste/rework collection, andhandling procedures related to the process andprocedures for containing spills







and control• Operating procedures for related packaging equipment• Routine maintenance procedures• Cleaning and sanitation procedures


Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Complector and related equipment and services• Flake to be processed• Sampling schedules and test procedures and equipment



required





FDFEODP2B Operate a deodorising processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a deodorising process to removethe disagreeable flavours and odours from product.



1. Prepare the deodorisingequipment and processfor operation







2. Operate and monitor thedeodorising process




2.4 The process is monitored to confirm that odour and flavourspecifications are met




3. Shut down thedeodorising process





FDFEODP2B Operate a deodorising process


RANGE STATEMENT





• Deodorising equipment may include tanks, pumps,deodoriser, vapour condenser, steam injection system,vacuum system, and cooling heat exchanger

• Materials may include bleached and neutralised oil, citricacid, hydrogenated oil, and filter bags









EVIDENCE GUIDE


Ability to: • Access workplace information to identify deodorisingprocess requirements



equipment condition to identify any signs of wear;confirming availability of tank space; selecting appropriatesettings and/or related parameters; cancelling isolation orlockouts as required; confirming that equipment is cleanand correctly configured for deodorising processrequirements; sensors and controls are correctlypositioned; any scheduled maintenance has been carriedout, and that all safety guards are in place andoperational

• Start, operate, monitor and adjust deodorising processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• time/temperature• vacuum pressure• steam flow/quantity• air contact• product quality

• Monitor supply and flow of materials to and from thedeodorising process




required to take deodorising process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility







Knowledge of: • Purpose and basic principles of the deodorising process• Basic operating principles of equipment. This may include


• The flow of the deodorising process and the effect ofoutputs on downstream processes

• Quality characteristics to be achieved by the deodorisingprocess

• Quality requirements of materials and effect of variation inoil quality on deodorising process performance



• Methods used to monitor the deodorising process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the deodorisingprocess and the related procedures and recordingrequirements

• Contamination/food safety risks associated with thedeodorising process and related control measures.



the deodorising process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to thedeodorising process



• Sampling and testing associated with deodorisingprocess monitoring and control






Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Deodorising process and related equipment and services• Oil to be deodorised• Sampling schedules and test procedures and equipment



required





FDFEOFL2A Operate a flake preparation processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

prepare the oil and water phases and set up, operate, adjust and shutdown the flaking process to prepare pastry margarine for furtherprocessing through a complector.



1. Prepare oil and emulsionphases

1.1 Oil requirements are identified and oil is transferred tomeet production requirements

1.2 Ingredients for addition are confirmed and available inrequired quantities

1.3 Ingredients are added to oil phase to meet recipespecifications

1.4 Oil stock is drawn to make emulsion1.5 Ingredients are added to water phase to meet recipe

specifications1.6 Oil stock and emulsion meet specifications

2. Prepare the drum andflaking equipment foroperation

2.1 Oil stock and water phase are available to meet operatingrequirements






3. Operate and monitor theflaking process









FDFEOFL2A Operate a flake preparation process


4. Shut down the flakingprocess




RANGE STATEMENT




• Workplace information may include Standard OperatingProcedures (SOPs), specifications/recipes, productionschedules and instructions, manufacturers' advice,standard forms and reports

• Preparation and processing equipment may includetanks, heat exchangers, ingredient addition systems,brine and tepid water loops, refrigeration system andflaking/drum

• Stages for oil phase typically include oil transfer andpasteurisation, addition of ingredients such as emulsifiersand other ingredients as required. Stages for emulsionstage typically include addition of brine and water to oilstock and addition of other ingredients as required. Theemulsion is then transferred to the flaking process




• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, steam, water, refrigeration, and compressed andinstrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify oil and emulsionphase preparation requirements


• Confirm supply of necessary oil type, ingredients foraddition and services

• Prepare oil and water phase according to procedures• Prepare emulsion according to procedures• Conduct pre-start checks on refrigeration and flaking

process. This may involve inspecting equipment conditionto identify any signs of wear; selecting appropriatesettings and/or related parameters; cancelling isolation orlockouts as required; confirming that equipment is cleanand correctly configured for processing requirements;valves and sensors and controls are correctly positioned;any scheduled maintenance has been carried out, andthat all safety guards are in place and operational

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required toconfirm process remains within specification. This mayinclude monitoring:• operation of addition/dosing equipment• drum speed• emulsion temperature• ammonia suction temperature• flake thickness• flake temperature• moisture level• salt level• evenness of curtain fall



• Demonstrate batch/product changeovers• Respond to and/or report equipment failure within level of





• Use process control systems




• Collect samples and conduct tests• Conduct routine maintenance• Clean and sanitize equipment




Knowledge of: • Principles of forming a water in oil emulsion. This includesan understanding of the type/s of emulsifiers used

• Purpose and basic principles of the flaking process. Thisincludes a basic understanding of stages of crystallisationof oil types used



• Quality characteristics to be achieved by each stage - oilphase, water phase and refrigeration/flaking process

• Quality requirements of oil and ingredients used andeffect of variation on process performance




• Contamination/food safety risks associated with theprocess and related control measures. This includes therisk of cross-contamination where tempered productmixes with untempered product


• OHS hazards and controls. This includes an awarenessof the risks of working with ammonia and procedures tofollow in the event of a leak





• Environmental issues and controls relevant to theprocess. This includes waste/rework collection andhandling procedures related to the process andprocedures for containing spills









Pre-requisite units









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



required





FDFEOFP2B Operate a fractionation processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down the fractionation process toseparate edible oils into two or more liquid and solid parts, each withdistinct physical and chemical properties.



1. Prepare the fractionationequipment and processfor operation







2. Operate and monitor thefractionation process




2.4 The process is monitored to confirm that fractionationproduct meets melting point specifications




3. Shut down thefractionation process





FDFEOFP2B Operate a fractionation process


RANGE STATEMENT





• Fractionation equipment may include tanks,crystallisation/seeder vessel, separators, pumps, andheat exchanger

• Fractionation methods may include dry, solvent anddetergent-based processes

• Materials may include crude tallow, and detergent• Processes may be batch or continuous, and apply to

single or multiple product types• Operators carry out changeovers within workplace








EVIDENCE GUIDE


Ability to: • Access workplace information to identify fractionationprocess requirements



equipment condition to identify any signs of wear;confirming availability of tank space; selecting appropriatesettings and/or related parameters; cancelling isolation orlockouts as required; confirming that equipment is cleanand correctly configured for fractionation processrequirements; sensors and controls are correctlypositioned; any scheduled maintenance has been carriedout, and that all safety guards are in place andoperational

• Start, operate, monitor and adjust fractionation processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• time/temperature• flow rates• vacuum• product quality

• Monitor supply and flow of materials to and from thefractionation process




required to take fractionation process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility







Knowledge of: • Purpose and basic principles of the fractionation process.This includes a basic understanding of the chemicalstructure of oil and the effect of fractionation on thisstructure


• The flow of the fractionation process and the effect ofoutputs on downstream processes

• Quality characteristics to be achieved by the fractionationprocess

• Quality requirements of oil for fractionation and effect ofvariation on fractionation process performance



• Methods used to monitor the fractionation process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in thefractionation process and the related procedures andrecording requirements

• Contamination/food safety risks associated with thefractionation process and related control measures



the fractionation process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to thefractionation process



• Sampling and testing associated with fractionation




process monitoring and control• Routine maintenance procedures• Cleaning and sanitation procedures


Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Fractionation process and related equipment and

services• Oil and chemicals required for the fractionation process• Sampling schedules and test procedures and equipment



required





FDFEOHP2B Operate a hydrogenation processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a hydrogenation process toimprove the hardness, viscosity, flavour and shelf-life of oils.



1. Prepare thehydrogenation equipmentand process for operation






2. Operate and monitor thehydrogenation process




2.4 The process is monitored to confirm that hydrogenatedproduct meets melting point and fat profile specifications




3. Shut down thehydrogenation process





FDFEOHP2B Operate a hydrogenation process


RANGE STATEMENT





• Hydrogenation equipment may include tanks, pumps,hydrogenation autoclave (reactor), vacuum system,hydrogen supply system, filtration system, and heatexchangers

• Materials used in hydrogenation may include neutralisedand bleached oils, catalyst, hydrogen, filter aid, filterpapers, cloths, and bags

• Processes may be batch or continuous, and apply tosingle or multiple product types








EVIDENCE GUIDE


Ability to: • Access workplace information to identify hydrogenationprocess requirements



equipment condition to identify any signs of wear;confirming availability of tank space; selecting appropriatesettings and/or related parameters; cancelling isolation orlockouts as required; confirming that equipment is cleanand correctly configured for hydrogenation processrequirements; sensors and controls are correctlypositioned; any scheduled maintenance has been carriedout, and that all safety guards are in place andoperational

• Start, operate, monitor and adjust hydrogenation processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• oil temperature• vacuum pressure• hydrogenation quantity and agitation• reaction rates• flow rates/quantity• air contact• product quality

• Monitor supply and flow of materials to and from thehydrogenation process




required to take hydrogenation process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility







Knowledge of: • Purpose and basic principles of the hydrogenationprocess. This includes a basic understanding of thechemical structure of oil and the effect of hydrogenationon this structure


• The flow of the hydrogenation process and the effect ofoutputs on downstream edible oils and fats processes

• Quality characteristics to be achieved by thehydrogenation process

• Quality requirements of oil, catalyst and filter aid as usedand effect of variation on hydrogenation processperformance



• Methods used to monitor the hydrogenation process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in thehydrogenation process and the related procedures andrecording requirements

• Contamination/food safety risks associated with thehydrogenation process and related control measures


• OHS hazards and controls. This includes anunderstanding of the hazards associated with the use ofhydrogen

• Requirements of different shutdowns as appropriate tothe hydrogenation process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage



• Hydrogenation process changeover procedures andresponsibilities

• Environmental issues and controls relevant to thehydrogenation process. This includes waste/reworkcollection and handling procedures related to the process






• Sampling and testing associated with hydrogenationprocess monitoring and control



Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Hydrogenation process and related equipment and

services• Oil, catalyst and filter aid as required for the

hydrogenation process• Sampling schedules and test procedures and equipment



required





FDFEOIN2B Operate an interesterification (IE) processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down an interesterification process torearrange the chemical composition of oil molecules.



1. Prepare theinteresterificationequipment and processfor operation






2. Operate and monitor theinteresterification process




2.4 The process is monitored to confirm that productmodification meets melting point and odour specifications




3. Shut down theinteresterification process





FDFEOIN2B Operate an interesterification (IE) process


RANGE STATEMENT





• Interesterification equipment may include tanks, reactor,washing/drying vessel, pumps, and filter system.Separators (centrifuges) may also be used to separate oilfrom wash water

• Materials used in interesterification may include catalyst,and wash water

• Processes may be batch or semi-continuous orcontinuous and apply to single or multiple product types








EVIDENCE GUIDE


Ability to: • Access workplace information to identify IE processrequirements



equipment condition to identify any signs of wear;confirming availability of tank space; selecting appropriatesettings and/or related parameters; cancelling isolation orlockouts as required; confirming that equipment is cleanand correctly configured for the IE process requirements;sensors and controls are correctly positioned; anyscheduled maintenance has been carried out, and that allsafety guards are in place and operational

• Start, operate, monitor and adjust the IE processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• time/temperature• agitation settings• moisture content• flow rates• contact time and reaction speed• vacuum• colour and soap content of oil

• Monitor supply and flow of materials to and from the IEprocess




required to take the IE process and related equipmentoff-line in preparation for cleaning and/or maintenancewithin level of responsibility

• Demonstrate batch/product changeover as required• Complete workplace records as required• Maintain work area to meet housekeeping standards






Knowledge of: • Purpose and basic principles of the IE process. Thisincludes a basic understanding of the chemical structureof oil and the effect of IE on this structure


• The flow of the IE process and the effect of outputs ondownstream edible fats and oils processes

• Quality characteristics to be achieved by the IE process• Quality requirements of materials and effect of variation

on IE process performance• Operating requirements and parameters and corrective



• Methods used to monitor the IE process. This mayinclude inspecting, measuring and testing as required bythe process. It requires awareness of inspection or testpoints (control points) in the IE process and the relatedprocedures and recording requirements

• Contamination/food safety risks associated with the IEprocess and related control measures



the IE process and workplace production requirements.This includes emergency and routine shutdowns andprocedures to follow in the event of a power outage




• Environmental issues and controls relevant to the IEprocess. This includes waste/rework collection andhandling procedures related to the process



• Sampling and testing associated with the IE processmonitoring and control






Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• IE process and related equipment and services• Deodorised oil required for interesterification and related

catalyst• Sampling schedules and test procedures and equipment



required





FDFEONP2B Operate a neutralisation processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a neutralisation process toremove impurities from crude oils.



1. Prepare the neutralisationequipment and processfor operation






2. Operate and monitor theneutralisation process




2.4 The process is monitored to confirm that neutralisedproduct meets FFA and soap target specifications




3. Shut down theneutralisation process





FDFEONP2B Operate a neutralisation process


RANGE STATEMENT





• Neutralisation equipment may include tanks, pumps,centrifugal separators, vacuum dryer, chemical additionsystem, and heat exchanger

• Materials used in neutralisation may include crude oil, hotwater, phosphoric acid, sodium hydroxide, and citric acid

• Processes may be batch or continuous, and apply tosingle or multiple product types








EVIDENCE GUIDE


Ability to: • Access workplace information to identify neutralisationprocess requirements



equipment condition to identify any signs of wear;confirming availability of tank space; selecting appropriatesettings and/or related parameters; cancelling isolation orlockouts as required; confirming that equipment is cleanand correctly configured for neutralisation processrequirements; sensors and controls are correctlypositioned; any scheduled maintenance has been carriedout, and that all safety guards are in place andoperational

• Start, operate, monitor and adjust neutralisation processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• oil temperature• pressures• flow rates/quantity• chemical dosage rate• product quality

• Monitor supply and flow of materials to and from theneutralisation process




required to take neutralisation process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility







Knowledge of: • Purpose and basic principles of the neutralisationprocess. This includes an understanding of the type ofalkali used. It may also require an understanding of thedegumming process to prepare oil for neutralisation


• The flow of the neutralisation process and the effect ofoutputs on downstream edible oils and fats processes

• Quality characteristics to be achieved by theneutralisation process

• Quality requirements of inputs and effect of variation in oilquality on neutralisation process performance



• Methods used to monitor the neutralisation process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in theneutralisation process and the related procedures andrecording requirements

• Contamination/food safety risks associated with theneutralisation process and related control measures



the neutralisation process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage



• Neutralisation process changeover procedures andresponsibilities

• Environmental issues and controls relevant to theneutralisation process. This includes waste/reworkcollection and handling procedures related to the process






• Sampling and testing associated with neutralisationprocess monitoring and control



Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Neutralisation process and related equipment and

services• Oil required for the neutralisation process and acid and

alkali materials as required by the process• Sampling schedules and test procedures and equipment



required





FDFEOSSP2A Operate a soap splitting processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a soap splitting process. Thismay also be referred to as an acid oil process. It covers the splitting ofsoap stock into an acid oil stream and an acid water stream.



1. Prepare the equipmentand soap splitting processfor operation


1.2 Machine components are adjusted to meet operatingrequirements




2. Operate and monitor thesoap splitting process




2.4 The process is monitored to confirm separation of acid oiland acid water streams



3. Shut down the soapsplitting process





FDFEOSSP2A Operate a soap splitting process


RANGE STATEMENT




• Soap splitting/acidification equipment typically includespumps, reactors, acid and steam addition systems andsettling tanks


• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, steam, water, compressed and instrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify soap stockprocessing requirements


• Confirm supply of soap stock, acid and services• Conduct pre-start checks. This may involve inspecting

equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;correctly configured for processing requirements;cancelling isolation or lockouts as required; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational. It also includesconfirming service supply

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required toconfirm process remains within specification. This mayinclude monitoring:• pH and temperature of reactors• pH and temperature of acid water• acid addition• tank levels• colour of acid oil• colour of acid water (minimum fatty matter in acid

water stream)• Monitor supply and flow of materials to and from the

process• Take corrective action in response to out-of-specification

results• Prepare acid oil for loading and delivery• Respond to and/or report equipment failure within level of

responsibility• Locate emergency stop functions on equipment; pH rises

and temperature drops• Follow isolation and lock out/tag out procedures as




• Use process control systems• Conduct routine maintenance• Clean equipment




Knowledge of: • Purpose and basic principles of soap splitting. Thisincludes an understanding of the process used to splitsoap stock and the end uses of each stream


• The flow of this process and the effect of outputs ondownstream processes. This includes an understandingof the impact of acid water pH on the performance of theeffluent plant and impact of allowing 'fatty' acid water toflow downstream

• Requirements of acid oil and acid water streams to beachieved

• The effect of variation in soap stock on the soap splittingprocess



• Methods used to monitor the production process. Thisincludes an understanding of the purpose and methodsused to conduct relevant tests. Tests typically include pH,moisture and FFA

• Contamination risks associated with the process andrelated control measures


• OHS hazards and controls. This may include awarenessof hazards associated with handling hazardoussubstances













Pre-requisite units




• FDFZPRCI2A Operate a process control interface• FDFOPTISP2A Implement sampling procedures• PMLTEST300A Perform basic tests• FDFOPTCRM2A Conduct routine maintenance





parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Process and related equipment and services• Materials to be processed• Sampling schedules and test procedures and equipment



required





FDFEOWP2B Operate a winterisation processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a winterisation process toremove waxes from partially refined oil.



1. Prepare the winterisationequipment and processfor operation







2. Operate and monitor thewinterisation process




2.4 The process is monitored to confirm that winterisedproduct meets cold test specifications




3. Shut down thewinterisation process





FDFEOWP2B Operate a winterisation process


RANGE STATEMENT





• Winterisation equipment may include tanks, pumps,chilling unit, winterising vessel, filtration equipment, andfilter aid addition system

• Materials used in winterisation may include deodorisedoil, filter aid, filter cloths, papers and/or bags









EVIDENCE GUIDE


Ability to: • Access workplace information to identify winterisationprocess requirements



equipment condition to identify any signs of wear;confirming availability of tank storage space; selectingappropriate settings and/or related parameters; cancellingisolation or lockouts as required; confirming thatequipment is clean and correctly configured forwinterisation process requirements; sensors and controlsare correctly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational

• Start, operate, monitor and adjust winterisation processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• temperature• vacuum• flow rates• tank levels• filter aid addition• product quality

• Monitor supply and flow of materials to and from thewinterisation process




required to take winterisation process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility







Knowledge of: • Purpose and basic principles of the winterisation process• Basic operating principles of equipment. This may include


• The flow of the winterisation process and the effect ofoutputs on downstream processes

• Quality characteristics to be achieved by the winterisationprocess

• Quality requirements of oil to be winterised and effect ofvariation on winterisation process performance



• Methods used to monitor the winterisation process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the processand the related procedures and recording requirements

• Contamination/food safety risks associated with thewinterisation process and related control measures



the winterisation process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to thewinterisation process. This includes waste/reworkcollection and handling procedures related to the process



• Sampling and testing associated with winterisationprocess monitoring and control






Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Winterisation process and related equipment and

services• Deodorised oil and filter aid as required for winterisation• Sampling schedules and test procedures and equipment



required





FDFFMCO2B Operate a grain conditioning processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a process to condition grain byadding water to create a moisture level required for the separation andreduction processes.

Unit Sector Flour Milling


1. Prepare the grainconditioning equipmentand process for operation







2. Operate and monitor thegrain conditioning process




2.4 The process is monitored to confirm that conditionedproduct meets grist moisture specifications

2.5 Conditioned product is stored according to food safetyrequirements




3. Shut down the grainconditioning process





FDFFMCO2B Operate a grain conditioning process


RANGE STATEMENT





• Grain conditioning equipment may include conditioningbins, mechanical/pneumatic stock transfer equipment,and automatic water addition equipment

• Grain conditioning may be a two-part process• Stock for the conditioning process may be clean grain

direct from the silo or cleaned wheat from the cleaningprocess




• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, vacuum, and compressed and instrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify conditioningprocess requirements


• Confirm supply of necessary materials and services• Confirm conditioning and lying times• Calculate water addition to suit machine and wheat type• Conduct pre-start checks. This may involve inspecting

equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat related equipment is clean and correctly configuredfor grain conditioning process requirements; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Start, operate, monitor and adjust conditioning processequipment to achieve required outcomes. This mayinclude monitoring control points and conducting tests asrequired such as moisture tests to confirm processremains within specification

• Monitor supply and flow of materials to and from theconditioning process




required to take conditioning process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility

• Demonstrate batch/product changeovers• Complete workplace records as required• Maintain work area to meet housekeeping standards






Knowledge of: • Purpose and basic principles of the conditioning process• Basic operating principles of equipment. This may include


• The flow of the conditioning process and the effect ofoutputs on downstream flour milling processes

• Quality characteristics to be achieved by the conditioningprocess

• Quality requirements of materials and effect of variationon conditioning process performance

• Types of grain and their qualities• Microbiological considerations in conditioning grain• Operating requirements and parameters and corrective



• Methods used to monitor the conditioning process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in theconditioning process and the related procedures andrecording requirements

• Contamination/food safety risks associated with theconditioning process and related control measures. Thisincludes an understanding of the potential risksassociated with out-of-specification lying times ofconditioned grain



the conditioning process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to theconditioning process. This includes waste/reworkcollection and handling procedures related to the process


• Basic operating principles of process control where








Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Conditioning process and related equipment and services• Materials required for the conditioning process• Sampling schedules and test procedures and equipment



required





FDFFMGC2B Operate a grain cleaning processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a cleaning process to screenimpurities from the grist prior to the conditioning process.



1. Prepare the grain cleaningequipment and processfor operation





1.5 The bin system is setup to meet production requirements1.6 Equipment performance is checked and adjusted as


requirements

2. Operate and monitor thegrain cleaning process




2.4 The process is monitored to confirm that stock meets gristspecifications

2.5 The process is monitored to confirm that impurity removalrate meets specifications




3. Shut down the graincleaning process





FDFFMGC2B Operate a grain cleaning process


RANGE STATEMENT





• Grain cleaning equipment may include intake equipment,day bins, screens, separators, aspirators,extractors/destoners, scourers, scales, dampers,measurers/mixers, impact grinders, and materialshandling equipment

• Raw materials for grain cleaning may include gristpreviously cleaned or dirty wheat which has beenaccepted by the mill








EVIDENCE GUIDE


Ability to: • Access workplace information to identify grain cleaningprocess requirements



equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat required screens are fitted and related equipment isclean and correctly configured for grain cleaning processrequirements; sensors and controls are correctlypositioned; any scheduled maintenance has been carriedout, and that all safety guards are in place andoperational

• Start, operate, monitor and adjust grain cleaning processequipment to achieve required outcomes. Monitoringincludes visual inspection and regular checking ofcollection points (filters and screens) and of overtail bags.Process adjustment is carried out to maintain efficientremoval of impurities with minimal removal of product

• Monitor supply and flow of materials to and from the graincleaning process




required to take grain cleaning process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility







Knowledge of: • Purpose and basic principles of the grain cleaningprocess


• The flow of the grain cleaning process and the effect ofoutputs on downstream processes

• Quality characteristics to be achieved by the graincleaning process

• Quality requirements of materials and effect of variationon grain cleaning process performance

• How and why various kinds of wheat are blended to makegrist

• Purpose of the break rolls• How and why the separation of endosperm takes place• Operating requirements and parameters and corrective



• Methods used to monitor the grain cleaning process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the graincleaning process and the related procedures andrecording requirements

• Contamination/food safety risks associated with the graincleaning process and related control measures



• Requirements of different shutdowns as appropriate tothe grain cleaning process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to the graincleaning process. This includes waste/rework collectionand handling procedures related to the process









Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Grain cleaning process and related equipment and

services• Materials required for the grain cleaning process• Sampling schedules and test procedures and equipment



required





FDFFMPP2B Operate a purification processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a separation and gradingprocess to remove particles of bran, with or without endosperm or germattached, from the stock flow.



1. Prepare the purificationequipment and processfor operation







2. Operate and monitor thepurification process




2.4 The process is monitored to confirm that particle size andquantity of stock meets specifications

2.5 Fine bran is removed from the semolina and the branproduct with endosperm attached is returned to thepurification process or scratch rolls for further processing




3. Shut down the purificationprocess





FDFFMPP2B Operate a purification process


RANGE STATEMENT





• Equipment used in the purification process is a series ofpurifiers with related dust collection systems, andmechanical/pneumatic stock transfer equipment

• Stock for purification is supplied from the scratch andsizing process








EVIDENCE GUIDE


Ability to: • Access workplace information to identify purificationprocess requirements



equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;fitting required screen sizes; cancelling isolation orlockouts as required; confirming that related equipment isclean and correctly configured for purification processingrequirements; sensors and controls are correctlypositioned; any scheduled maintenance has been carriedout, and that all safety guards are in place andoperational

• Start, operate, monitor and adjust purification processequipment to achieve required outcomes. This mayinclude monitoring control points, conducting inspectionsand making adjustments to stock flow, feed gates andscreens as required to confirm purification processremains within specification. Monitoring and adjustmentincludes checking efficiency to remove offal with minimalproduct removal

• Monitor supply and flow of materials to and from thepurification process




required to take purification process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility







Knowledge of: • Purpose and basic principles of the purification process• Basic operating principles of equipment. This may include


• The flow of the purification process and the effect ofoutputs on downstream flour milling processes

• Quality characteristics to be achieved by the purificationprocess

• Quality requirements of materials and effect of variationon purification process performance



• Methods used to monitor the purification process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the purificationprocess and the related procedures and recordingrequirements

• Contamination/food safety risks associated with thepurification process and related control measures



the purification process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to thepurification process. This includes waste/rework collectionand handling procedures related to the process










Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Purification process and related equipment and services• Materials to be purified• Sampling schedules and test procedures and equipment



required





FDFFMSG2B Operate a scalping and grading processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a production process for theseparation of the break stock (chop) into appropriate flows to the nextbreak, purifiers and sizing rolls.



1. Prepare the scalping andgrading equipment andprocess for operation







2. Operate and monitor thescalping and gradingprocess




2.4 The process is monitored to confirm that particle size ofstock meets specifications




3. Shut down the scalpingand grading process





FDFFMSG2B Operate a scalping and grading process


RANGE STATEMENT





• Stock from break rolls of reduction rolls supplies thescalping and grading process

• Scalping and grading equipment includes plainsifters andaccessories, and mechanical/pneumatic stock transferequipment. Supporting systems may includecompressors, aspirators and filtrators








EVIDENCE GUIDE


Ability to: • Access workplace information to identify scalping andgrading process requirements



equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat related equipment is clean and correctly configuredfor scalping and grading process requirements; sensorsand controls are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Start, operate, monitor and adjust scalping and gradingprocess equipment to achieve required outcomes. Thismay include monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring includes regular inspection ofcollection points and sifter outlets to confirm processefficiency and visual inspection of product samples toconfirm particle size

• Monitor supply and flow of materials to and from thescalping and grading process

• Adjust and clean screens• Take corrective action in response to out-of-specification


responsibility• Locate emergency stop functions on equipment• Demonstrate batch/product changeovers• Follow isolation and lock out/tag out procedures as

required to take scalping and grading process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility







Knowledge of: • Purpose and basic principles of the scalping and gradingprocess


• The flow of the scalping and grading process and theeffect of outputs on downstream flour milling processes

• Quality characteristics to be achieved by the scalping andgrading process

• Quality requirements of materials and effect of variationon scalping and grading process performance



• Methods used to monitor the scalping and gradingproduction process. This may include inspecting,measuring and testing as required by the process. Itrequires awareness of inspection or test points (controlpoints) in the scalping and grading process and therelated procedures and recording requirements

• Contamination/food safety risks associated with thescalping and grading process and related controlmeasures



the scalping and grading process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage




• Environmental issues and controls relevant to thescalping and grading process. This includes waste/reworkcollection and handling procedures related to the process



• Sampling and testing associated with process monitoring




and control• Routine maintenance procedures• Cleaning and sanitation procedures


Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Scalping and grading process and related equipment and

services• Stock required for the scalping and grading process• Sampling schedules and test procedures and equipment



required





FDFFMSS2B Operate a scratch and sizing processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a separation process to ensureas little bran as possible is in the remaining endosperm.



1. Prepare the scratch andsizing equipment andprocess for operation







2. Operate and monitor thescratch and sizing process




2.4 The process is monitored to confirm that particle size andquantity of stock meet specifications




3. Shut down the scratchand sizing process





FDFFMSS2B Operate a scratch and sizing process


RANGE STATEMENT





• Equipment used in the scratch and sizing process mayinclude reduction rolls, plainsifters, purifiers, flakedisruptors, detachers, and mechanical/pneumatic stocktransfer equipment

• Stock for the scratch and sizing is supplied from thescalping and grading process








EVIDENCE GUIDE


Ability to: • Access workplace information to identify scratch andsizing process requirements



equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat related equipment is clean and correctly configuredfor scratch and sizing process requirements; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Start, operate, monitor and adjust scratch and sizingprocess equipment to achieve required outcomes. Thismay include monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring includes:• correct product type/quantity• roll releases• even spread of feed across rolls• mill balance• even grind/correct particle size

• Monitor supply and flow of materials to and from thescratch and sizing process




required to take scratch and sizing process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility







Knowledge of: • Purpose and basic principles of the scratch and sizingprocess


• The flow of the scratch and sizing process and the effectof outputs on downstream flour milling processes

• Quality characteristics to be achieved by the scratch andsizing process

• Quality requirements of materials and effect of variationon scratch and sizing process performance



• Methods used to monitor the scratch and sizingproduction process. This may include inspecting,measuring and testing as required by the process. Itrequires awareness of inspection or test points (controlpoints) in the scratch and sizing process and the relatedprocedures and recording requirements

• Contamination/food safety risks associated with thescratch and sizing process and related control measures



• Requirements of different shutdowns as appropriate tothe scratch and sizing process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to the scratchand sizing process. This includes waste/rework collectionand handling procedures related to the process









Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Scratch and sizing process and related equipment and

services• Stock required for the scratch and sizing process• Sampling schedules and test procedures and equipment



required





FDFFMWB2B Operate a break roll processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a process to separate bran fromthe endosperm.



1. Prepare the break rollequipment and processfor operation







2. Operate and monitor thebreak roll process




2.4 The process is monitored to confirm that bran separatedfrom endosperm meets specifications




3. Shut down the break rollprocess





FDFFMWB2B Operate a break roll process


RANGE STATEMENT





• Break roll equipment may include break rolls (roller mills),mechanical/pneumatic stock transfer equipment, branfinishers, and dressing machines

• Grain for the break roll process is supplied from thecleaning and conditioning processes

• By-products may include wheat germ, pollard, bran, andsemolina








EVIDENCE GUIDE


Ability to: • Access workplace information to identify break rollprocess requirements



equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat related equipment is clean and correctly configuredfor break roll process requirements; sensors and controlsare correctly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational

• Start, operate, monitor and adjust reduction processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring includes:• correct product type/quantity• moisture content of incoming wheat• break roll releases• even spread of feed across rolls• mill balance• even grind/correct particle size

• Monitor supply and flow of materials to and from thebreak roll process




required to take break roll process and related equipmentoff-line in preparation for cleaning and/or maintenancewithin level of responsibility







Knowledge of: • Purpose and basic principles of the break roll process.This includes an understanding of how and why theendosperm separation takes place


• The flow of the break roll process and the effect ofoutputs on downstream processes

• Quality characteristics to be achieved by the break rollprocess

• Quality requirements of materials and effect of variationon break roll process performance. This includes anunderstanding of the effect of moisture variation andrelated scope to adjust process throughput


• Typical equipment faults and related causes. Thisincludes recognition of signs and symptoms of faultyequipment and early warning signs of potential problems.It also includes an understanding of symptoms of chokes,blockages or breaches and action required to clear

• Methods used to monitor the break roll process. This mayinclude inspecting, measuring and testing as required bythe process. It requires awareness of inspection or testpoints (control points) in the break roll process and therelated procedures and recording requirements

• Contamination/food safety risks associated with the breakroll process and related control measures

• Common causes of variation and corrective actionrequired.


• Requirements of different shutdowns as appropriate tothe break roll process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage




• Environmental issues and controls relevant to the breakroll process. This includes waste/rework collection andhandling procedures related to the process









Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Break roll process and related equipment and services• Conditioned grain suitable for the break roll process• Sampling schedules and test procedures and equipment



required





FDFFVFP2B Operate a freezing processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a freezing process.Unit Sector Fruit and Vegetable


1. Prepare the freezingprocess for operation







2. Operate and monitor thefreezing process








3. Shut down the freezingprocess





FDFFVFP2B Operate a freezing process


RANGE STATEMENT





• Freezing methods may include air freezing, contactfreezing and cryogenic freezing







EVIDENCE GUIDE




• Confirm supply of necessary materials and services• Prepare materials as required• Conduct pre-start checks. This may involve inspecting


• Start, operate, monitor and adjust the freezing processand equipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. This can involve monitoring:• tunnel and product temperatures• throughput• removal of frozen waste product from equipment• visually inspecting product



• Demonstrate procedure to defrost tunnels as required• Respond to and/or report equipment failure within level of





• Use process control systems• Conduct product/batch changeovers• Collect samples and conduct tests• Conduct routine maintenance• Clean and sanitzse equipment




Knowledge of: • Purpose and basic principles of freezing. This includes anunderstanding of the changes which occur to productduring freezing

• Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents, status and purpose of guards, basicprinciples and operation of refrigeration system,equipment operating capacities and applications, and thepurpose and location of sensors and related feedbackinstrumentation

• The flow of this process and the effect of product outputon downstream processes

• Quality characteristics to be achieved by the freezingprocess

• Effect of raw material characteristics on the freezingprocess














• Sampling and testing associated with process monitoring




and control• Routine maintenance procedures• Cleaning and sanitation procedures


Pre-requisite units








food safety, quality and environmental requirements• Production schedule and batch instructions• Specifications, control points and processing parameters• Information on equipment capacity and operating

parameters• Freezing process and related equipment and services• Materials to be frozen• Sampling schedules and test procedures and equipment


required• Documentation and recording requirements and

procedures





FDFHYCH2A Operate a creamed honey manufactureprocess

Unit Descriptor This is a Specialist unit. It covers the skills and knowledge required toset up, monitor, and adjust a process to produce creamed honey.

Unit Sector Honey



1.1 Liquid and seed honey is confirmed and available to meetproduction requirements



1.4 Processing/operating parameters are set to meet safetyand production requirements



2. Operate and monitor thecreamed honeymanufacture process








3. Shut down the creamedhoney manufactureprocess





FDFHYCH2A Operate a creamed honey manufacture process


RANGE STATEMENT



• Legislative requirements are typically reflected inprocedures and specifications. Legislation relevant to thisindustry includes the Food Standards Code, labellingincluding weights and measures legislation; andlegislation covering food safety, environmentalmanagement, occupational health and safety,anti-discrimination and equal opportunity


• Production processes may be partly or fully automated.While processes vary, typical stages include addition ofseed honey, holding, mixing/working and temperaturecontrol


• Equipment may include jacketed tanks/vats, buffer tanks,mixers/homogenisers, scraped surface heat exchangers,agitators and pumps


• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, water, and compressed and instrumentation air




EVIDENCE GUIDE




• Confirm supply of necessary materials and services. Thisincludes selecting appropriate seed honey. It may alsorequire selection of more than one liquid honey to meetrequired product characteristics

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameterssuch as temperature and agitation settings; cancellingisolation or lockouts as required; confirming thatequipment is clean and correctly configured forprocessing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required toconfirm process remains within specification








• Use process control systems• Demonstrate batch/product changeovers• Collect samples and conduct tests• Conduct routine maintenance• Clean and sanitize equipment




Knowledge of: • Basic principles of crystallisation. Aspects include anunderstanding of crystal structure and where appropriate,methods used to reduce crystal size, the effects oftemperature and agitation on crystal formation,appropriate ratio of seed to liquid honey and factors thatinfluence the crystallisation process including moisturecontent and crystal size

• Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents, status and purpose of guards;,equipmentoperating capacities and applications and the purposeand location of sensors and related feedbackinstrumentation. It also includes knowledge of servicesrequired and action to take if services are not available

• Quality and organoleptic characteristics of different typesof honey processed

• Quality characteristics to be achieved by the final productand related test methods used to confirm quality

• Quality requirements of seed and liquid honey used andthe effect of variation on the final product

• Operating requirements, parameters and corrective actionrequired where the process is outside specified operatingparameters. Typical operating parameters includeambient and processing temperatures, agitation speedsand holding times and temperatures


• Methods used to monitor each stage of the productionprocess. This may include inspecting, measuring andtesting as required. It requires awareness of inspection ortest points (control points) in the process and the relatedprocedures and recording requirements

• Contamination/food safety risks associated with theprocess and related control measures. This relatesspecifically to air inclusion and moisture content andrelated methods of control


• Factors that affect the stability and shelf-life of thefinished product and options to extend shelf-life. Thisincludes storage conditions for packed product















Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Process and related equipment and services• Seed and liquid honey• Sampling schedules and test procedures and equipment



required




FDFICIM2A Operate an ice manufacturing processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, monitor, and adjust a process to manufacture ice. This unit isappropriate where the process requires operator monitoring andadjustment. Where the process is highly or fully automated, this unitmay not apply.

Unit Sector Ice


1. Prepare the ice makingequipment and processfor operation

1.1 Water suitable for ice manufacture is available to meetoperating requirements






2. Operate and monitor theice making process








3. Shut down the ice makingprocess





FDFICIM2A Operate an ice manufacturing process


RANGE STATEMENT



• Legislative requirements are typically reflected inprocedures and specifications. Legislation relevant to thisindustry includes the Food Standards Code, labellingincluding weights and measures legislation; andlegislation covering food safety, environmentalmanagement, occupational health and safety,anti-discrimination and equal opportunity


• Ice production includes tube, block, plate, shell and flakeice. Ice is bagged or filled into insulated bins

• Equipment may include tube, plate and scraped surfaceheat exchangers

• Related processes may include water purification,crushing, pressing and/or bagging

• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, refrigerant, water, and compressed andinstrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify ice productionrequirements



equipment condition to identify any signs of wear;checking refrigerant levels; selecting appropriate settingsand/or related parameters; cancelling isolation or lockoutsas required; confirming that equipment is clean andcorrectly configured for processing requirements; sensorsand controls are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoring:• temperature range• ice thickness• cycle time• head pressures

• Monitor ambient temperature and adjust the process asrequired







• Use process control systems• Clean and sanitize equipment




Knowledge of: • Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents, status and purpose of guards, equipmentoperating capacities and applications, and the purposeand location of sensors and related feedbackinstrumentation. It also includes knowledge of servicesrequired and action to take if services are not available

• The stages in the ice making cycle. Depending onprocess, this includes a make and defrost stage

• Water treatment prior to use• Operating requirements, parameters and corrective action

required where operation is outside specified operatingparameters


• Adjustments required to take account of ambienttemperature




• Storage requirements for packed ice• 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. This includes waste/rework collection andhandling procedures related to the process








Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Process and related equipment and services• Water to be used for ice manufacture• Documentation and recording requirements and


required





FDFIMEPC4A Establish process capabilityUnit Descriptor This unit covers the skills and knowledge required to study process

data to determine process capability using statistical process control(SPC) techniques. This unit applies to people responsible forestablishing control charts and related sampling plans.

Prerequisite Unit(s) FDFTECNUM4A Describe and analyse data using mathematicalprinciplesFDFOPTSPC2A Apply principles of statistical process control

Unit Sector Information Management


1. Prepare to conduct acapability study

1.1 The scope and purpose of the process is identified1.2 A representative data sample is determined1.3 Data collection techniques are selected1.4 Data is collected to meet sampling requirements

2. Analyse data to determineprocess capability

2.1 Appropriate statistical analysis techniques are selectedand applied

2.2 Process stability and extent of variation are identified2.3 The target mean for the process is identified2.4 Process control parameters are calculated2.5 Related data sampling requirements are specified

RANGE STATEMENT


Range description • Data collection is specified and may be collected byothers

• Data analysis typically involves the use of statisticalanalysis software


FDFIMEPC4A Establish process capability


EVIDENCE GUIDE


Ability to: • Establish process scope, boundaries and relatedinformation on process purpose. This can includedocumentation such as product or process specificationswhere available

• Apply sampling techniques to determine nature andextent of data collection to provide a reliable indication ofprocess performance

• Select and apply data collection methods. Where datacollection is automated, this may involve use of software.Where data collection is to be carried out by operators, itinvolves communicating requirements and designingappropriate formats for recording data

• Confirm that data collected is complete and complies withsampling requirements

• Identify characteristics of a normal distribution• Apply appropriate statistical techniques including

standard deviation to analyse data. This includestechniques to distinguish common and special causes ofvariation

• Establish process capability. This includes establishingupper and lower limits and instructions for identifying andresponding to trends

• Develop a related data sampling plan including advice onsampling regimes following corrective action

Knowledge of: • Data collection requirements and techniques for collectionof actual (quantitative) and variable data

• Techniques to determine and validate a sampling plancapable of providing reliable information representative ofthe total population

• Appropriate formats for presenting sampling planrequirements and related communication systems

• Workplace conventions/formats for presenting andmonitoring process capability information. This type ofinformation is typically presented as a control chartincluding a target mean, upper and lower limits andadvice on how to interpret and confirm trends. It may alsoinclude upper and lower warning limits

• Process knowledge to identify possible causes of specialvariation

• The difference between a stable process and a capableprocess and action required to improve processperformance in each case





Pre-requisite units

The pre-requisites for this unit are:

• FDFOPTSPC2A Apply principles of statistical processcontrol

• FDFTECNUM4A Describe and analyse data usingmathematical principles


This unit should be assessed together with core units and otherunits of competence relevant to the function or work role.



• Workplace processes and procedures• Workplace documentation including process

specifications/purpose, sampling plan and control chartformats, and related data collection methods such as logsheets

• Data collection and analysis software and systems asappropriate

• Communication systems





FDFIMMIA4A Manage Internal AuditsUnit Descriptor This unit is designed to support the management of internal audit

processes across a range of programs including but not limited tohealth and safety, quality and environmental management. This unit isappropriate where internal audit processes are conducted to supportexternally audited programs. Auditing must occur in an area that theperson is not directly responsible for and where they are required tofollow a formal, structured process. In addition to this standard, anauditor would typically work within the audit procedures as outlined inISO 10011.

When conducting a food safety audit the unit FDFFSCFSAA Conductfood safety audits should be used.



1. Plan an audit 1.1 The purpose and scope of the audit is negotiated andagreed

1.2 Information and resources required to conduct the auditare identified and secured

1.3 An audit schedule is developed and negotiated to meetaudit scope and timelines

2. Prepare for an audit 2.1 Audit information sample and collection tools aredetermined

2.2 Roles, responsibilities and authority levels of the auditteam are identified and communicated to audit teammembers as appropriate

2.3 Affected work areas/personnel are informed of scheduleand advised of their role in the process

3. Monitor the audit process 3.1 Information collected is adequate, representative andmeets audit requirements

3.2 Information is analysed to assess adequacy ofperformance against program objectives

3.3 Records are reviewed to confirm compliance with theprogram

3.4 Compliance with the program is observed in the workplace3.5 Areas requiring corrective action are identified3.6 Obstacles to achieving audit within agreed timelines are

identified and addressed


FDFIMMIA4A Manage Internal Audits


4. Report and follow up auditoutcomes

4.1 Situations presenting an imminent and serious risk to theprogram objectives are identified and reportedimmediately in accordance with reporting requirements

4.2 Audit reports are prepared to address audit scoperequirements

4.3 The results of the audit are communicated to appropriatepersonnel according to audit purpose and requirements

4.4 A corrective action plan is developed and negotiatedwithin level of responsibility

4.5 Implementation of corrective action as set out in thecorrective action plan is monitored and confirmed

4.6 Where corrective action does not meet the correctiveaction plan requirements, follow up action istaken/reported according to level of responsibility andaudit purpose

KEY COMPETENCIES

Key Competency Performance Level

Communicating ideas and information -

Collecting analysing and organising information -

Planning and organising activities -

Working with others and in teams -

Using mathematical ideas and techniques -

Solving problems -

Using technology -




RANGE STATEMENT


Range description • Audits may be conducted against workplace programsand/or legislative requirements

• Audits may be undertaken for advisory or regulatorypurposes and may be led by internal or external auditors

• Audits may be conducted by individuals or involve anaudit team

• A corrective action plan identifies non-conformance,corrective actions, date by which action must be takenand any other follow up requirements. Depending on thenature and scope of an audit, the auditor may not beresponsible for identifying appropriate corrective action.However, it is a requirement that they have the technicalknowledge to do so or involve a technical expert

• Appropriate communication skills and techniques musttake account of English language, literacy and technicalskill base of workplace personnel

• Information collection typically includes reviewingworkplace records, conducting interviews, observingworkplace practice and collecting other relevantinformation as required

• Detailed procedures and techniques for conducting auditsare currently defined by ISO 10011. This standard isunder review




EVIDENCE GUIDE


Ability to: • Identify roles and responsibilities of personnelparticipating in the audit process

• Establish and negotiate audit purpose and scope to meetthe workplace and legislative requirements

• Clarify program objectives and evaluation criteria to beapplied. Where appropriate, this includes identifying legalcompliance requirements

• Establish the audit sequence, activities and timelines• Identify roles, responsibilities and competencies required

to conduct an audit and confirm that the requiredcompetencies are available within the project team whereappropriate

• Identify and locate information required to conduct theaudit

• Review workplace documentation to confirm that requiredinformation is available

• Select and apply appropriate data collection tools toprovide information on both program outcomes andprocesses

• Establish an audit plan and timetable and communicatethe plan to relevant work areas/personnel. This mayinclude allocating tasks to match requirements of theaudit and competencies of the audit team

• Assess information collected against program objectivesand evaluation criteria to identifycompliance/non-compliance

• Identify any changes that have occurred in the workplacesince initiating the program or since the last programaudit that could affect program outcomes

• Identify, investigate and record evidence ofnon-compliance

• Assess severity of non-compliance and take immediateaction to report non-compliance that presents animminent and serious risk to achievement of programobjectives. Action must comply with company auditprocedures and with legal responsibilities where relevant

• Based on the audit findings, assess the adequacy of theprogram under review. This includes verifying thatinformation used to establish methods of controllinghazards is adequate and correct. Technicalexperts/accessing external technical resources may beused to support verification. Conclusions on auditoutcomes should be objective and capable of duplication,given the evidence collected

• Where findings indicate either a failure to comply with theprogram or inadequacy of the program, investigate anddetermine the causes of non-conformance and identifycorrective action requirements

• Communicate audit findings including corrective actions




and timeframes with relevant work areas/personnel. Thismay include negotiating/securing required resources

• Report the findings of the audit in an appropriate format tomeet the requirements of the workplace and legalcompliance where relevant




Knowledge of: • The purpose and intent of the program being audited.This includes an understanding of the requirements ofrelevant national, state and local government legislationrelating to program purpose and requirements

• Auditor roles, responsibilities and legal obligations asrelevant to the audit purpose. This includes anunderstanding of the responsibilities of both internal andexternal auditors, and the different types of auditors andof authorised officers who may be involved in the auditprogram. It also includes an understanding of legalresponsibilities for reporting imminent and seriousnon-conformities

• Requirements and procedures for certification/registrationof auditors and authorised officers according to audit type

• The frequency and scope of audit requirements to meetlegal obligations

• Appropriate ethical conduct of auditors as set out incodes of ethics of auditors and additional requirements asmay be determined by the workplace

• The purpose and stages involved in the audit process.This may include compliance with ISO audit standards asappropriate to audit requirements

• Workplace information and related informationmanagement systems

• Techniques for collecting information. This includesawareness of appropriate sampling techniques,information collection methods and the strengths andweaknesses of each method to ensure data is adequateand representative. This may include an understanding oftechniques as identified by ISO 10011

• Data analysis methods relevant to the audit process• Communication skills and techniques such as appropriate

questioning, observation and related communication skillsto support information collection, appropriate to theworkplace

• Technical knowledge relevant to the program beingaudited in order to verify the adequacy of:• hazard identification processes• control methods. This includes knowledge of industry

standards/practice• monitoring and record keeping• validation processes• corrective action/process improvement procedures

• Where program control methods or limits vary fromindustry standards or where there are no industrystandards, technical knowledge required to assess dataused by the business to validate acceptable limits. Thismay be addressed by identifying and involvingappropriate technical expertise

• Competency standards and related assessment andtraining options to support program implementation

• Information management and communication systems todocument and communicate audit outcomes in




appropriate formats


Pre-requisite units

The pre-requisites for this unit are:

• FDFOPTPAP3A Participate in audit processes

And the relevant program-related unit/s. These may include:

• FDFCORHS2A Implement occupational health and safetysystems and procedures

• FDFCORQAS2A Implement quality systems andprocedures

• FDFOPTENV2A Implement environmental policies andprocedures


This unit should be assessed together with core units and otherunits of competence relevant to the function or work role. Inaddition, the following optional units may be relevant:


• FDFOPTTG3A Lead work teams and groups• BSBCMN405A Analyse and present research information• FDFPLDMP5A Design and maintain programs to support

legal compliance



• Workplace program and related documentation• Relevant legislation• Audit procedures and standards. This includes any

external standards relevant to the audit, such as ISOstandards

• Advice on related technical industry standards and codesof practice

• Information systems and data collection technology• Reporting formats/requirements• Workplace/personnel access as required to collect

data/observe compliance





FDFIMMWB4A Manage a work area within budgetUnit Descriptor This unit covers the skills and knowledge required to plan, allocate and

monitor work to achieve required outcomes within budget allocations.This unit would typically apply to a team leader function where the teamleader is required to reach decisions on resource utilisation withinbudget constraints.



1. Identify and plan withinbudget parameters

1.1 Budget requirements and parameters are identified1.2 Resources are identified, confirmed and allocated to

achieve production schedule within budget

2. Monitor resourceutilisation against budget

2.1 Performance is monitored to identify actual/potentialvariance to budget

2.2 Variances to budget are identified, investigated andreported according to workplace reporting requirements

2.3 Potential failure to achieve targets within budget areidentified and communicated to appropriate personnel in atimely manner

2.4 Action is taken to minimise negative impact of variance

3. Communicate budgetinformation

3.1 Budget information is made available to relevantpersonnel in a timely manner

3.2 Budget information is reported in the appropriate formatand timelines according to workplace reportingrequirements

3.3 Contributions are made to the development of workplacebudgets

RANGE STATEMENT


Range description • Work planning and allocation to achieve outcomes withinbudget is consistent with company policies andprocedures, regulatory and licensing requirements,legislative requirements, and industrial awards andagreements and takes account of OHS andenvironmental impact of scheduling arrangements

• Budgets may include but are not limited to addressinglabour costs; materials costs; yield/volume and relatedefficiency parameters; equipment costs; and handling,storage and transport costs

• Communication of budget information includes consultingthe work team on budget related issues, providing promptinformation on performance against budget and reportingbudget information to relevant personnel in the requiredformat


FDFIMMWB4A Manage a work area within budget


EVIDENCE GUIDE


Ability to: • Identify budgets relevant to the work function and role• Identify resource requirements of the production process

and match these to availability, options and constraints.This depends on the nature of budget management. Forexample, when applied to managing within labour costs,availability includes available numbers and skill levels ofoperators; options may include use of permanents,overtime and/or casuals, and constraints may include therelative costs associated with each of these options

• Secure, confirm and allocate required resources to meetproduction schedule within budget parameters

• Monitor resource utilisation to confirm capability toachieve production schedule within existing resourceallocation. This may require calculation of yield

• Interpret budgets to track performance outcomes• Identify situations where achievement of required

outcomes within budget is not possible. Investigatecauses of variance and take appropriate action withinlevel of responsibility

• Identify the impact on budget of production-relateddecisions. For example, structuring rosters andscheduling holidays, adjusting production volume, andscheduling equipment maintenance

• Identify opportunities to improve performance againstbudget

• Communicate information on budget performance toothers in the work area. This may include providinginformation on key performance indicators (KPIs)

• Record and report budget information in the requiredformats

• Participate in budget development processes within levelof responsibility




Knowledge of: • The basis on which budgets developed for the work areaare constructed. This includes an understanding of theinformation supplied to budget planners, and how to readand interpret budget information and apply it tomonitoring/reviewing work performance

• Basic accounting concepts including fixed and variablecosts, rate of return, methods of allocating indirect costs,methods of measuring investment value

• Accounting models. This includes the difference betweentraditional accounting approaches and more recentdevelopments including accounting implications of valueadded management, life cycle costing and triple bottomline

• Company approach to cost management so thatdecisions on resource allocation are within both budgetallocations and company philosophy/preferred approach

• Resource requirements to meet production and relatedcosts

• Process knowledge to identify factors likely to impact onachieving budget

• Relevant personnel and departments to beconsulted/advised of budget information. This includes anunderstanding of the information relevant to eachgroup/person and the importance of providing accurateand timely information to each of the stakeholders

• Options for maximising resource utilisation andminimising costs

• Communication skills to consult and communicate withrelevant personnel

• Recording systems and requirements• Process improvement procedures


Pre-requisite units




• FDFPLSCP4A Schedule and manage production• BSBCMN405A Analyse and present research information






• Budgets and associated information and communicationsystems

• Production area and related functions and resources• Relevant standard operating procedures• Workplace information recording systems, requirements

and procedures





FDFFSACA Assess compliance with food safetyprograms

Unit Descriptor This unit covers skills and knowledge required to assess complianceagainst an approved food safety program where the program issupported by a prescriptive template or tool or where compliance ischecked against a food safety program that has been validated by atechnical expert.

This unit is based on and equivalent to the guideline food safety unitGFSACA Assess compliance with food safety programs.

Application of the Unit This unit may apply to regulatory, commercial or internal auditors.

When applied to assessing compliance of food safety programsin low risk food businesses or processes, the following unit mustbe pre or co-assessed with this unit:

FDFFSCOMA Communicate and negotiate to conduct food safetyaudits

When applied to assessing compliance of food safety programsin medium risk food businesses or processes, the following unitsmust be pre or co-assessed with this unit:


FDFFSCHZA Identify, evaluate and control food safety hazards

When applied to assessing compliance of food safety programsin high risk food businesses or processes, the following unitsmust be pre or co-assessed with this unit:


FDFFSCHZA Identify, evaluate and control food safety hazardsand any unit/s relevant to the specified high risk business orprocess.

Unit Sector No sector assigned


FDFFSACA Assess compliance with food safety programs



1. Plan the audit 1.1 An audit plan is developed to meet the audit scope. Theplan is capable of delivering the required outcomes withinresource and time allocations and includes:1.1.1 audit purpose, scope and relevant template/s or

approved food safety program1.1.2 activities and responsibilities1.1.3 audit timing (as required by legislation and/or

client)1.1.4 timetable for each stage of the audit1.1.5 resource requirements1.1.6 personnel required to participate in the audit1.1.7 reporting requirements1.1.8 audit follow up and completion procedures.

1.2 Communication protocols are established to facilitate theeffective exchange of information and suited to the auditeeenvironment

2. Review and assess foodsafety programs

2.1 The documented food safety program and relatedprocedures and pre-requisite programs are assessed toconfirm that legal and client requirements are addressedas determined by the audit scope

2.2 The food business method of identifying and analysingfood safety hazards is reviewed to establish that:2.2.1 templates or the approved food safety program are

correctly selected to meet audit scope2.2.2 templates or the approved food safety program are

appropriately adapted to suit the needs of thebusiness without adversely affecting food safety

2.3 Documented verification records are reviewed to confirmthat the requirements of the food safety program are beingmet

2.4 Corrective actions required where processes are identifiedas not meeting targets or critical limits are assessed toconfirm they meet the requirements of the template orfood safety program

2.5 Food safety pre-requisite programs are assessed toconfirm they are appropriate for the food business/industrysector to maintain a safe food environment

2.6 Food safety program documents are reviewed toconfirm currency, accuracy and adequacy to facilitatemaintenance of an adequate food safety program




3. Review and assessimplementation of foodsafety programs

3.1 Evidence is collected and assessed to confirm that:3.1.1 documented programs and procedures are

working effectively, reflect actual practice and areconsistently applied

3.1.2 food safety monitoring and corrective actions arecarried out according to procedure

3.1.3 food safety pre-requisite programs are effectiveand consistently followed

3.1.4 food safety records are completed and provide anaccurate record of events

3.1.5 records are accessed and analysed to confirmeffective program maintenance in accordance withthe template or food safety program

3.1.6 food safety skills and knowledge of food businesspersonnel is commensurate with their work role

3.1.7 procedures to internally monitor, assess, updateand improve the food safety program areimplemented

4. Manage the audit process 4.1 Audit progress is monitored against the audit plan and anyvariation to plan is identified and addressed

4.2 Circumstances requiring the audit plan to be adjusted areidentified and negotiated in a timely manner

4.3 Audits address audit scope and are conducted within timeand resource constraints to meet quality and professionalstandards

4.4 The audit process is reviewed to identify opportunities forimprovement

5. Consolidate auditoutcomes

5.1 Audit evidence is analysed and assessed to identify anyareas of non-compliance with legislation and/or clientrequirements as appropriate to the audit scope

5.2 Non-conformities are identified and classified as agreedby the audit plan

5.3 Non-conformities are reported in accordance with agreedclient and/or legislative requirements

5.4 Audit reports and/or certificates are prepared andsubmitted or presented as required to meet regulatory andclient requirements

5.5 A corrective action implementation plan defining proposedactions and timelines developed by the auditee isreviewed by the auditor to confirm that template or foodsafety program requirements are met

5.6 Audit findings are reviewed to confirm that evidence issufficient as defined by the template or approved foodsafety program

6. Confirm and close outcorrective actions

6.1 Implementation and effectiveness of corrective action ismonitored and verified against the template or theapproved food safety program

6.2 Audit records are maintained to record corrective actions




REQUIRED SKILLS AND KNOWLEDGE

This describes the essential skills and knowledge and their level, required for this unit.

Ability to:

1 Identify work processes and work flow. This includes the ability to describe each processstep and identify food safety hazards

2 Confirm that the food business has undertaken required preliminary work. This includesidentifying food to be covered by the food safety program, the food and the method ofdistribution are defined, customers and intended use of food is identified, the process isdescribed (for example, flowchart) and the food business has checked their work foraccuracy and completeness

3 Conduct research to identify, collect and analyse evidence4 Plan and organise audit activities5 Communicate to support evidence collection and outcome presentationKnowledge of:

1 Required content and scope of food safety programs as defined in the National FoodSafety Standard 3.2.1 or other relevant standards

2 Purpose and minimum requirements of risk-based approaches to managing food safetyhazards. This includes an understanding of the role of prescriptive templates or approvedfood safety programs in supporting a risk based approach and the process used to validatethese tools

3 Guidelines on customising and implementing industry templates or approved food safetyprograms

4 Legal requirements of food businesses5 Legal liability of auditors and protection against litigation and professional practice issues.

This includes an understanding of the circumstances under which an auditor could beprosecuted and insurance requirements

6 Audit activities and principles. This includes an understanding of the guidelines on auditstages and activities as outlined in ISO 19011:2002

7 Personal attributes required of food safety auditors. This includes knowledge of thepersonal attributes as outlined in ISO 19011:2002 and may include additional systemowner requirements

8 Role, responsibilities and powers of enforcement agencies, authorised officers andcommercial auditors. This includes an understanding of reporting responsibilities, legalliability of auditors and delegation of authority to commercial auditors as may apply insome states

9 Information handling and management system protocols. This includes issues such asrights of access to information, maintenance of confidentiality of audit information andreports and information dissemination requirements

10 Evidence appropriate for use in audit processes. This includes an understanding of thedifference between objective and hearsay evidence and methods for recording andmanaging evidence to provide reliable reference information in the event that evidence ischallenged

11 Vocabulary and terms relating to food safety programs. This includes terms and jargon todescribe technical processes, industry standards and common biological and chemicalterms

12 Common biological, physical and chemical hazards that may occur in the food businessand appropriate methods of control and critical limits as outlined in the approved foodsafety program or template

13 The impact of (1) the design and construction of premises and (2) the selection, applicationand condition of equipment, on food safety as defined in Food Safety Standard 3.2.3

14 Role of pre-requisite programs in controlling hazards. This includes an understanding ofthe relationship between pre-requisite programs and risk-based approaches including




HACCP to controlling food safety hazards15 Circumstances, implications and responsibilities in the event that the auditee requests that

the audit ceases16 Circumstances and authority to initiate cessation of an audit17 Methods to assess skill requirements and options to confirm that the responsible personnel

within the food business have the required skills and knowledge of food safety and foodhygiene relevant to the food business

KEY COMPETENCIES







Solving problems -

Using technology -

RANGE STATEMENT

The range statement relates to the unit of competency as a whole. It allows for different workenvironments and situations that may affect performance. Bold italicised wording, if used in thePerformance Criteria, is detailed below. Add any essential operating conditions that may be presentwith training and assessment depending on the work situation, needs if the candidate, accessibility ofthe item, and local industry and regional contexts.

Technical expert The requirements of a technical expert are determined by thesystem owner. System owners may include governmentregulators as well private system owners.

Audit scope The scope describes the purpose, extent and boundaries of theaudit. This may include:

• physical locations• products• processes• time period covered by the audit• extent of authority of the auditor




Food safety program Food safety programs include both pre-requisite programs anda risk based analysis of food safety hazards to determinerequired control measures to eliminate, prevent or reducehazards. Minimum legal requirements for food safety programsare specified in National Food Safety Standard 3.2.1 or otherrelevant legislative requirements.

The food safety program may be based on a template orexternally developed program that is adapted to the needs ofthe business.

Pre-requisite programs Pre-requisite programs are also referred to as supportprograms, or acronyms such as Good manufacturing practice(GMP), Good Agricultural Practice (GAP) and Good HygienePractice (GHP).

Pre-requisite programs can be divided into 2 categories.

Infrastructure and maintenance programs may include:

• layout, design and construction of buildings and facilities• supplies of air, water energy and other utilities• equipment including preventative maintenance, sanitary

design and accessibility for maintenance and cleaning• support services including waste and sewage disposal

Operational pre-requisite programs may include:

• personal hygiene• cleaning and sanitation• pest control• measures for the prevention of cross-contamination• packaging and labelling procedures• supplier assurance• chemical storage• employee training• maintenance• calibration• document control• internal audit programs• traceability and recall programs• on-farm food safety schemes• inspecting and testing regimes, including analytical and

microbiological testing




Legal requirements The scope of the audit determines and may be determined byfood safety legislation which may include:

• Food standards code• Relevant state legislation and related codes of practice

including industry sector-specific legislation and relatedcodes of practice such as that relating to meat, seafood,dairy and primary production and processing

• Regulatory and commercial requirements relevant toimporting countries

• Commonwealth legislation (eg. Export Control Act)

Other legislation which may impact on the conduct of a foodsafety auditor may include legislation covering:

• OHS, anti-harassment, anti-discrimination and industrialrelations

• Trade practices legislation• Environmental risk management• Legal contracts or agreements

Food businesses A food business refers to a business, enterprise or activitywhere food is produced, processed, stored, displayed and/orsold. It may also include primary producers.

Food safety programdocuments

This may include:

• Documented statements of food safety policy andobjectives

• Documented procedures and records• Documented complaints register• Documents and records to ensure the effective

development, implementation and updating of the foodsafety program

Risk-based approaches Risk-based approaches to controlling food safety are typicallybased on HACCP, described in the Codex Alimentariusguidelines.

EVIDENCE GUIDE

The evidence guide provides advice on assessment and must be read in conjunction with thePerformance Criteria, Required Skills and Knowledge, the Range Statement and the AssessmentGuidelines for the Training Package.

Overview of Assessment 1 Assessment may occur in a real or simulated audit contextwhere the simulated context provides access to a typicallow, medium or high risk food or primary industry business.The assessee must have access to a documented foodsafety program and related documents and records.




Critical aspects forassessment and evidencerequired to demonstratecompetency in this unit

1 All elements, performance criteria, and required skillsand knowledge are critical and must be assessed.Critical aspects of assessment must include thefollowing:1.1 Confirm that the food safety program and/or template

is appropriate to the activities of the business.1.2 Review food safety program records to assess

compliance against the approved food safety programand/or template.

1.3 Collect and analyse evidence to confirm that the foodsafety program is consistently followed and controls allcritical risks.

1.4 Identify circumstances where variation or customisingof the template or food safety program requires furthervalidation.

1.5 Submit non-compliance reports to clearly identify theaspects of the food safety program that have brokendown/need further development in order to preventrecurrence.




FDFFSBM4A Audit bivalve mollusc growing andharvesting processes

Unit Descriptor This unit specifies the outcomes required to support a food safety auditof food safety programs of bivalve mollusc producers.

The unit covers on-shore and wild growing, harvesting, cleaning,post-harvest handling and storage, stock movement, depuration (whereapplicable) and wet storage. This unit does not cover the skills andknowledge to audit the classification of growing areas.

This unit supports relevant legislation such as food standards containedin the Food Standards Code and industry codes of practice relating tovalidation and verification of a HACCP-based food safety program, andshould be read in conjunction with these documents.

Both regulatory and commercial audit system owners may specifyadditional certification requirements of auditors eligible to audit foodsafety programs within their system.

Prerequisite Unit(s) FDFFSCHZA Identify, evaluate and control food safety hazardsFDFFSCFSAA Conduct food safety auditsFDFFSCOMA Communicate and negotiate to conduct food safetyaudits

Application of the Unit This unit supports the role of a food safety auditor responsible forauditing a bivalve mollusc growing and harvesting process.These audits would typically occur within the context of auditing aHACCP-based food safety program that defines relatedprerequisite program requirements. The audits are supported bystate and territory government regulations for prescribingprocesses and requirements relating to the production of bivalvemolluscs.



1. Identify and assess foodsafety hazards and relatedcontrol options for growingand harvesting bivalvemolluscs.

1.1 Microbiological food safety hazards that could presenta risk in bivalve molluscs at the point of consumption areidentified by type and origin and assessed to determinerisk level and control requirements.

1.2 Chemical food safety hazards that could present a riskin bivalve molluscs at the point of consumption, includingtoxin presence, are identified by type and assessed todetermine risk level and control requirements.

1.3 Control requirements and methods to ensure that bivalvemolluscs meet food safety objectives are identified.

2. Confirm that appropriateevidence supportsvalidation of growing andharvesting bivalvemolluscs.

2.1 Validation evidence and records are reviewed to confirmthat an appropriate level of validation has been applied.

2.2 Evidence used by the business to validate the process isidentified and assessed to confirm that it is credible andadequate to meet the food safety objective.


FDFFSBM4A Audit bivalve mollusc growing and harvesting processes


3. Verify bivalve molluscgrowing and harvestingprocesses.

3.1 System records required to support verification againstrelevant shellfish quality programs are identified,collected and reviewed.

3.2 Business documentation is reviewed and inspections areconducted to confirm that facilities and equipment designand components comply with regulatory and businessstandards .

3.3 Business documentation is reviewed and inspections areconducted to confirm that operational monitoring andtesting procedures and frequency meet regulatoryrequirements, and industry and business standards.






Required skills include:

• interpret and apply relevant legislation, codes of practice and technical standardsrelating to growing and harvesting bivalve molluscs

• identify microbiological and chemical food safety hazards to be controlled by bivalvemollusc growing and harvesting practices and processes

• inspect facilities and equipment to confirm that regulatory, industry and businessstandards are met

• review evidence used to validate the food safety control process• review workplace records and other documentation to verify that the food safety program

relating to the production of bivalve molluscs meets regulatory requirements and iseffectively implemented.

Required knowledge and understanding include:

• regulations, codes of practice, guidelines and Australian standards relating to productionof bivalve molluscs and related role of government in overseeing implementation ofshellfish quality programs

• basic biology and physiology of bivalve molluscs and related sources of food safety risk• pathogens that can occur in bivalve molluscs and related survival and growth

characteristics and control methods• chemicals that pose a food safety risk in bivalve molluscs• sources of environmental contamination that can present a food safety risk in the

growing and harvesting of bivalve molluscs and related food safety controls, includingrisks associated with both on-shore and wild fisheries

• sources of information on acceptable and legal product quality requirements, includinglegal limits to ensure product safety

• classifications applying to harvesting areas, system for monitoring and determiningstatus, sources of advice on classification and methods of communicating classificationinformation

• sources of pre- and post-harvest contamination and related control requirements• risks and related control methods to prevent cross-contamination, including sorting and

cleaning• prerequisite programs required to support bivalve mollusc growing and harvesting• basic principles of water sampling and test methods• principles and associated control measures relating to effective purging of shellfish,

including methods such as relaying and depuration, when practised in accordance withstate legal and regulatory requirements

• risks associated with depuration and wet storage methods, and related control methodsand prerequisite programs that meet legal requirements

• sources of pre- and post-harvest contamination such as sewage, algal biotoxins andvibrio organisms and related control requirements

• stock handling and storage risks and control methods• facilities and equipment used in the growing and harvesting of bivalve molluscs,

including features required to meet regulatory requirements.




KEY COMPETENCIES







Solving problems -

Using technology -

RANGE STATEMENT


Microbiological food safetyhazards may include:

• Hepatitis A virus• Norwalk virus• Vibrio parahaemolyticus• V. vulnificus• Salmonell spp• pathogenic Escherichia coli.

Bivalve molluscs mayinclude:

• oysters: Pacific, Sydney rock, Angassi (native) and pearl• mussels• pipis• clams: strawberry and razor• cockles: sand, dog, blood and mud• scallops and other adductor bivalves, including pearl

oyster meat (unless adductor muscle only).

Chemical food safetyhazards may include:

• common origins of chemical contamination, including:• phycotoxins: harmful algal blooms such as amnesic

shellfish poisoning (ASP), neurotoxic shellfishpoisoning (NSP), diarrhetic shellfish poisoning (DSP)and paralytic shellfish poisoning (PSP)

• pesticides• water additives• toxic metals• polychlorinated biphenyls (PCBs).

Validation refers to: • obtaining evidence to confirm that a HACCP-based foodsafety program is complete and effective and will deliverthe expected food safety outcomes.




Validation evidenceconfirms that controlmeasures are capable ofbeing consistently effectiveand may include:

• the application of:• existing Australian legislative requirements• challenge tests• peer reviewed scientific papers• targeted scientific reports• validation already carried out in other jurisdictions and

recognised by the responsible authority• mathematical modelling, e.g. predictive microbiology

models• industry codes of practice (where implementation by food

business is verified during audits).

Verification refers to: • methods and procedures used to carry out monitoring,including sampling and testing to provide evidence thatthe specifications set by relevant legislation and codes ofpractice continue to be met.

Shellfish qualityprograms refer to:

• Australian shellfish quality assurance programsadministered by state and territory shellfish controlauthorities.

Business standards referto:

• standards or technical specifications set by the systemowner based on and in addition to regulatoryrequirements that relate specifically to food safety.

Relevant legislation, codesof practice and technicalstandards relating tobivalve molluscs mayinclude:

• Food Standards Code 4.2.1: Primary Production andProcessing Standards for Seafood (Australia only),FSANZ

• Australian Shellfish Quality Assurance Program:Operations Manual, May 2005

• AQIS Australian Shellfish Quality Assurance Program,Export Standards, 2004

• state and territory regulations, codes of practice andguidelines.

Role of government inoverseeing implementationof shellfish qualityprograms:

• responsibility and capacity to control food safety hazardsis shared by the state and territory governments throughthe relevant state authority responsible for managingharvesting areas and by the farmer who is responsible formanaging the harvest and post-harvest handling andstorage.




Prerequisite programs: • are also referred to as support programs or acronymssuch as good agricultural practice (GAP) and goodhygienic practice (GHP)

• can be divided into two categories:• infrastructure and maintenance programs which may

include:• layout, design and construction of buildings and

facilities• supplies of air, water, energy and other utilities• equipment, including sanitary design, preventative

maintenance, calibration and cleaning and sanitation• support services, including waste and sewage

disposal• pest control

• operational prerequisite programs which may include:• personal hygiene• measures for the prevention of cross-contamination• packaging and labelling procedures• chemical storage• employee training• document control• internal audit programs• traceability and recall programs• product integrity and security• cold chain management• inspecting and testing regimes, including analytical

and microbiological testing• control of non-conforming product, processes and

facilities.

Relaying refers to: • the transfer of shellfish from growing areas (includingrestricted areas, conditional restricted areas in the openstatus or conditional approved areas in the closed status)to approved or conditional approved areas in the openstatus

• the purpose of relaying is to achieve the requiredreduction of pathogens as measured by the faecalcoliform indicator group or poisonous or deleterioussubstances that may be present, using the ambientenvironment as a treatment process.




EVIDENCE GUIDE



A person who demonstrates competency in this unit must beable to provide evidence that they can verify that food safetyprograms covering growing and harvesting bivalve molluscsmeet regulatory, industry and business standards.

Assessment must confirm that the candidate can participate inaudits of HACCP-based food safety programs to demonstrateability and knowledge of technical aspects of growing andharvesting bivalve molluscs. Audit scenarios must include atleast one audit involving relaying, depuration or wet storage.

Context of and specificresources for assessment

Competency is to be assessed in an environment wherebivalve molluscs are grown and harvested.

Assessment is to occur under standard and authorised workpractices, safety requirements and environmental constraints.

The following resources must be available:

• food safety programs covering bivalve mollusc growingand harvesting processes

• food safety related documentation typical of commercialgrowing and harvesting businesses and used for thepurpose of verification

• plant and equipment that would typically be used in acommercial bivalve mollusc growing and harvestingbusiness.

Method of assessment This unit only covers the technical skills and knowledge relatedto the specific area of risk. Generic food safety auditing skillsand knowledge are covered in prerequisite units. Whileparticipation in audit processes should follow good auditingpractice as specified by prerequisite units, formal assessmentof generic food safety auditing competence does not need tobe repeated when assessing this unit.

The audits conducted for the purpose of assessment must bewitnessed by an auditor competent to audit bivalve molluscgrowing and harvesting processes.

Assessment methods must satisfy the endorsed AssessmentGuidelines of the FDF03 Food Processing Industry TrainingPackage.




FDFFSCC4A Audit a cook chill processUnit Descriptor This unit specifies the outcomes required to support a food safety audit

of food safety programs that include extended life cook chill processes.

The unit applies to cook chill products which are minimallyheat-processed foods distributed as chilled products with defined shelflife.

This unit supports relevant legislation such as food standards containedin the Food Standards Code and industry codes of practice relating tothe validation and verification of a HACCP-based food safety program,and should be read in conjunction with these documents.



Application of the Unit This unit supports the role of a food safety auditor responsible forauditing extended and short shelf life cook chill processes. Auditprocesses would typically occur within the context of auditing aHACCP-based food safety program that defines relatedprerequisite program requirements.



1. Identify and assess foodsafety hazards and relatedcontrol options for cookchill processes.

1.1 Microbiological food safety hazards that could present arisk in cook chill products at the point of consumptionare identified by type, origin and food association andassessed to determine the significance of the hazard.

1.2 Chemical food safety hazards that could present a risk incook chill products at the point of consumption, includingtoxin presence, are identified by type and food associationand assessed to determine risk level and controlrequirements.

1.3 Physical food safety hazards that could present a risk inthe food at the point of consumption are identified andassessed to determine risk level and control requirements.

1.4 Cook chill process control requirements and methods areidentified to ensure that finished, cook chill products meetfood safety objectives.

2. Confirm that appropriateevidence supportsvalidation of the cook chillprocess.

2.1 Validation evidence and records are reviewed to confirmthat appropriate level of validation has occurred.

2.2 Evidence used by the business to validate the process isidentified and assessed to confirm that it is credible andadequate to achieve the food safety objective.


FDFFSCC4A Audit a cook chill process


3. Verify the food safetyprogram for a cook chillprocess.

3.1 System records required to support verification areidentified, collected and reviewed.









• interpret and apply relevant legislation, standards, codes of practice and technicalspecifications relating to heat treatment of foods in a cook chill process

• identify target micro-organisms to be controlled by a cook chill process according to foodtype and cold chain capacity

• inspect extended and short shelf life cook chill plant and equipment to confirm thatregulatory, industry and business standards are met

• apply principles of heat treatment and chilling to assess suitability of extended and shortshelf life cook chill processes to ensure food safety objectives are achieved

• review workplace records, including results of process monitoring and documentation ofcorrective actions to verify that the food safety program relating to cook chill processesis being implemented according to the prescribed process

• review evidence used to validate the food safety control process• confirm methods and evidence used to test the reliability of cook chill processes.


• regulations, codes of practice, guidelines, technical standards and Australian standardsrelating to all forms of cook chill processing of foods

• target organisms that can occur in extended and short shelf life cook chill foods, theirsurvival and growth characteristics and related control methods

• principles of heat treatment and chilling as they apply to extended and short shelf lifecook chill processing methods and product types

• criteria used to specify heat treatment, cooling, storage and shelf life parameters forextended and short shelf life cook chill products

• factors that impact on heat and chilling processes meeting food safety objective• prerequisite programs required to support effectiveness of cook chill processes• operational principles of commercial extended and short shelf life cook chill equipment,

including equipment features required to meet regulatory requirements and criticalfactors to be controlled to ensure delivery of heating and chilling processes that meetfood safety objective

• features of the environment in which cook chill foods are distributed, including riskfactors

• foods and preparation methods that present a particular risk to vulnerable populations,including cross-contamination risks associated with multi-tasking and cold chainmaintaining temperatures during storage, transport and distribution

• principles of packaging to form a suitable seal and impact of processing parameters andconditions on packaging integrity

• effect of characteristics and pre-processing of raw materials and post-process packagingon the stability and safety of the product

• labelling requirements for extended and short shelf life cook chill products• food safety risks and controls to avoid post-process contamination of heat-treated

product• principles of test methods and frequency to confirm the effectiveness of cook chill

processes and meet regulatory, industry and business standards.




KEY COMPETENCIES







Solving problems -

Using technology -

RANGE STATEMENT


Cook chill products mayinclude:

• long shelf life refrigerated foods• short shelf life refrigerated foods• heat-treated refrigerated foods packed for extended shelf

life (HTRF)• refrigerated processed foods of extended durability

(REPFED)• sous vide foods.

Physical food safetyhazards include:

• an understanding of physical standards that may presentparticular risks to vulnerable populations either due to thenature of the food, the preparation method and/or thepreparation environment.











Equipment includes: • cook tanks• self-stirring kettles• combi ovens• re-thermalisation cabinets• brat pans• blast chillers• water baths• pump-fill station.



Test methods include: • conducting studies of process evaluation• conducting studies of equipment performance.

Relevant legislation,standards, codes ofpractice and technicalspecifications relating toretort requirements mayinclude:

• relevant sections of the Australia New Zealand FoodStandards Code

• Australia Cook Chill Council, Guidelines for Chilled FoodProduction Systems Including Food Safety Programs,2000

• Validation and Verification of Heat Treatment Equipmentand Processes (ANZDAC - draft)

• international protocols such as those of CODEXAlimentarius Commission

• AQIS Code of Hygienic Practice for Heat-treatedRefrigerated Foods Packaged for Extended Shelf Life,1992

• state and territory regulations, codes of practice andguidelines.

Target organisms aredependent on the food andcold chain capacity andinclude:

• Listeria monocytogenes• Clostridium botulinum• Bacillus cereus• Salmonella• Yersinia enterocolitica.




Prerequisite programs: • are also referred to as support programs, or acronymssuch as good manufacturing practice (GMP), goodagricultural practice (GAP) and good hygienic practice(GHP)

• can be divided into two categories:• infrastructure and maintenance programs which may

include:• layout, design, construction and amenities of

buildings and facilities• supplies of air, water, energy and other utilities• equipment, including sanitary design, preventative



• operational prerequisite programs which may include:• personal hygiene• measures for the prevention of cross-contamination• packaging and labelling procedures• supplier assurance• chemical storage• employee training• document control• internal audit programs• traceability programs• product integrity and security• cold chain management• inspecting and testing regimes, including analytical

and microbiological testing• control of non-conforming product, including product

recall programs.

Vulnerable populations aredefined by the sensitivity ofa population. Examples ofsectors serving food tovulnerable populationsinclude:

• hospitals• aged care facilities• childcare centres• organisations delivering to housebound people.

Packaging methodsinclude:

• controlled atmosphere (CA) packaging• modified atmosphere (MA) packaging• vacuum packing.




Additional referencematerial includes:

• Food Standards Australia New Zealand, Safe FoodAustralia - A Guide to the Food Safety Standards,Australian Government Printing Service, Canberra

• Campden & Chorleywood Food Research Association,Code of Practice for the Manufacture of Vacuum andModified Atmosphere Packaged Chilled Foods, (1996)

• Campden & Chorleywood Food Research Association,The Microbiological Safety of Sous-Vide Processing,Technical Manual No 39, (1992).

EVIDENCE GUIDE



A person who demonstrates competency in this unit must beable to provide evidence that they can verify cook chillprocesses for a range of foods to meet regulatory, industry andbusiness standards. They must also demonstrate capacity toconfirm that appropriate validation has occurred.

Assessment must confirm that the candidate can:

• identify target organisms for a range of foods• determine capacity of distribution chain to control

temperature parameters• determine requirements of specific extended and short

shelf life cook chill methods for a range of products• participate in audits of HACCP-based food safety

programs to demonstrate ability and knowledge oftechnical aspects of extended and short shelf life cookchill processes - audit scenarios must include:• a five-day cook chill process• a kettle or cook tank cook chill process• a sous vide cook chill process.

For given scenarios where prescribed cook chill processingrequirements are not met, assess adequacy of evidence usedto determine response procedures.





Competency may be assessed in an actual workplace orsimulated environment that provides access to the requiredresources.


The following resources should be made available:

• food safety programs covering extended and short shelflife cook chill processes

• food safety-related documentation typical of commercialbusinesses producing extended and short shelf life cookchill products and used for the purpose of verification

• evidence or documentation relevant to extended andshort shelf life cook chill processes that would typically beused by commercial businesses producing extended andshort shelf life cook chill products to support validationprocesses

• plant and equipment that would typically be used bycommercial businesses producing extended and shortshelf life cook chill products.


Audits conducted for the purpose of assessment must bewitnessed by an auditor competent to audit extended and shortshelf life cook chill processes.

Assessment methods must satisfy the endorsed AssessmentGuidelines of FDF03 Food Processing Industry TrainingPackage.




FDFFSCFSAA Conduct food safety auditsUnit Descriptor This unit covers the skills and knowledge required to verify and confirm

validation of food safety programs in the context of food safetylegislation and client requirements.

This unit is based on and equivalent to the guideline food safety unitGFSCFSAA Conduct food safety audits

Application of the Unit At the time of writing the terms and definitions relating to the auditprocess were consistent with and further described in theinternational standard ISO/IEC 19011:2002, ' Guidelines onquality and/or environmental management systems auditing'.

Users of this unit should refer to the current the ISO standard andcurrent food safety legislation.

This unit applies to conducting on-site audits and is relevant toregulatory and commercial food safety system auditors.

This unit must be pre or co-assessed with:



When applied to conducting food safety audits of high risk foodbusinesses or processes, additional unit/s relevant to thespecified business or process may be required.



FDFFSCFSAA Conduct food safety audits



1. Plan the audit 1.1 Audit scope is identified and defines the extent of theaudit to meet legislative and audit client requirements

1.2 Audit criteria meet legislative and client requirements1.3 The definition and levels of non-conformity and related

reporting responsibilities are identified consistent withlegislative requirements and client requirements

1.4 Evidence required to address audit scope and criteria isidentified and appropriate collection methods areselected

1.5 Food safety management system documents arereviewed to determine adequacy for the purposes of theaudit

1.6 An audit plan is developed to meet the requirements offood safety legislation and client needs. The plan iscapable of delivering the required outcomes withinresource and time allocations and includes:1.6.1 audit purpose, scope and criteria1.6.2 definitions and levels of non-conformity1.6.3 activities and responsibilities1.6.4 audit timing (as required by legislation and/or

client)1.6.5 timetable for each stage of the audit1.6.6 resource requirements1.6.7 personnel required to participate in the audit1.6.8 reporting requirements1.6.9 audit follow up and completion procedures.

1.7 Communication protocols are established to facilitate theeffective exchange of information and suited to the auditeeenvironment

2. Conduct the audit 2.1 Information on the audit scope and methodology iscommunicated in an effective and timely manner

2.2 Stages and activities and of the audit process are followed2.3 Methods used by the food business to carry out

preliminary work, identify food safety hazards andassess level of risk are reviewed to confirm that they areappropriate and correctly applied

2.4 Evidence used by the food business to supportidentification of control measures and establish controllimits is identified and evaluated to determine adequacyand relevance

2.5 Methods used by the food business to control hazards anddetermine corrective action where processes are identifiedas not meeting targets or critical limits are reviewed toconfirm they are adequate, effective and appropriate

2.6 Evidence is collected to confirm that the documented foodsafety policies and procedures are working effectively,reflect actual practice and are consistently applied




3. Manage the audit process 3.1 Audit progress is monitored against the audit plan and anyvariation to plan is identified and addressed

3.2 Circumstances requiring the audit plan to be adjusted areidentified and negotiated in a timely manner

3.3 Audits address audit scope and are conducted within timeand resource constraints to meet quality and professionalstandards

3.4 The audit process is reviewed to identify opportunities forimprovement

4. Consolidate auditoutcomes

4.1 Evidence is analysed and assessed to identify any areasof non-compliance with legislation and/or clientrequirements as appropriate to the audit scope

4.2 Non-conformities are identified and classified as agreedby the audit plan

4.3 Non-conformities are reported in accordance with agreedclient and/or legislative requirements

4.4 Audit findings are communicated to the auditee4.5 Audit reports and/or certificates are prepared and

submitted or presented as required to meet regulatory andclient requirements

4.6 Corrective actions proposed by the auditee in response tonon-conformances are reviewed for compliance with thetemplate or food safety program

4.7 Audit findings are reviewed to confirm that evidence isappropriate and sufficient and findings are accurate

4.8 The food safety management system is reviewed toidentify areas of potential improvement of the systemaccording to audit scope

5. Confirm and close outcorrective actions

5.1 Implementation and effectiveness of corrective actions aremonitored and verified and any variation to the food safetyplan is identified and addressed

5.2 Audit records are maintained to record corrective actions






Ability to:

1 Locate relevant commonwealth, state and/or territory legislation, regulations and relatedcodes of practice and determine the legal responsibilities of food businesses relevant tothe industry sector

2 Plan and manage audit activities3 Communicate information in ways appropriate to the purpose and the audience and to

facilitate opening and closing meetings4 Negotiate and facilitate audit processes. This includes following meeting procedures and

resolving issues5 Select and use research skills relevant to audit activities including researching technical

sources to validate food safety programs and collecting evidence to support verification6 Consolidate audit findings based on objective evidence7 Prepare records and reports appropriate to the purpose of the audit and the needs of the

auditee and the client (system owner/regulator)Knowledge:

Auditor Roles and Responsibilities

1 Audit activities and stages. This includes an understanding of the guidelines on auditstages and activities as outlined in ISO 19011:2002

2 Personal attributes required of food safety auditors. This includes knowledge of thepersonal attributes as outlined in ISO 19011:2002 and may include additional clientrequirements

3 Role, responsibilities and powers of enforcement agencies, authorised officers andcommercial auditors. This includes an understanding of reporting responsibilities, legalliability of auditors and delegation of authority to commercial auditors as may apply insome states

4 Relevant competencies and certification/registration criteria and processes applying toboth regulatory and commercial auditors

5 Audit management to develop and implement an audit against an agreed plan. Thisincludes an understanding of the scope/level of authority to revise the resource andallocate time allocations to take account of variation to plan

Food Safety Management Systems

1 Purpose and intent of each element of a food safety management system2 The underlying principles of risk-based approaches to controlling food safety hazards

including HACCP as described in the Codex Alimentarius Guidelines3 Vocabulary and terms relating to food safety. This includes terms and jargon to describe

technical processes, industry standards and common biological and chemical terms4 Food safety management system knowledge relevant to the system being audited. This

includes an understanding of system requirements, definitions and levels ofnon-compliance and related reporting responsibilities as defined by legal and managementsystem requirements

5 The interaction between different types of management systems. This includes anawareness of the impact of food safety decisions on other management systems such asOHS, quality, environmental risk management and animal welfare

6 Technical knowledge required to assess the adequacy of the food safety managementsystem performance and corrective actions

7 Role of pre-requisite programs in controlling hazards. This includes an understanding ofthe relationship between pre-requisite programs and risk-based approaches includingHACCP to controlling food safety hazards

8 Information handling and management system protocols. This includes issues such as




rights of access to information, maintenance of confidentiality of audit information andreports and information dissemination requirements

Food Safety Legislation

1 The purpose and intent of food safety legislation. This includes knowledge of sources ofinformation on importing country requirements and of requirements of countries andretailer driven systems in importing markets

2 The content covered by the Food Standards Code and/or other relevant standards3 The structure and responsibilities of commonwealth, state and territory government

departments and local government to manage and implement food safety legislation. Thisincludes understanding of where to find information on relevant commonwealth,state/territory legislative requirements, product or industry sector legislation andregulations and import and export market requirements

4 Knowledge of the regulatory framework and specific legislation relevant to the audit. Thisincludes an understanding of relevant risk profiling or classification systems where theyapply

5 Sources of information on legislation and codes governing primary production and primaryprocessing

6 Requirements for scheduling and conducting further auditing as determined by food safetylegislation and/or client system requirements

7 Legal liability of auditors and protection against litigation and professional practice issues.This includes an understanding of the circumstances under which an auditor could beprosecuted and insurance requirements

8 The role of auditors when called on to provide evidence as a witness in courtFood Safety Audit Processes

1 Preliminary work required to identify food to be covered by the food safety program, definethe food and the method of distribution, identify customers and intended use of food,describe the process (flowchart) and check accuracy and completeness

2 Methods used identify food safety hazards and assess food safety hazard risk levels takingaccount of severity and likelihood of occurrence

3 Methods used to identify critical control points and establish critical limits, suited to thenature of the hazard, the requirements of the audit and the industry sector

4 Methods used to validate control techniques and critical limits. This includes knowledge ofindustry or sector codes of practice, technical standards and research

5 Types of evidence. This includes an understanding of the difference between objective andhearsay evidence and methods for recording and managing evidence to provide reliablereference information in the event that evidence is challenged

6 Evidence collection methods including record sampling and sample analysis. This includesan understanding of the evidence collection options relevant to a given audit situation, thereliability of each collection method and the range/extent of evidence collection methodsrequired to ensure that audit outcomes are objective, consistent, fair and reliable

7 Methods to assess skill requirements and options to confirm that the responsible personnelwithin the food business have the required skills and knowledge of food safety and foodhygiene relevant to the food business

8 Circumstances, implications and responsibilities in the event that the auditee requests thatthe audit ceases

9 Circumstances and authority of an auditor to initiate cessation of an audit10 Understanding of the context in which audits are conducted. This includes an awareness of

workplace culture and preferred communication methods, industry, process and/or productknowledge and related jargon

11 Information recording requirements and audit reporting requirements




KEY COMPETENCIES







Solving problems -

Using technology -

RANGE STATEMENT


Audit scope The scope describes the purpose, extent and boundaries of theaudit. This may include:

• physical locations• products• processes• time period covered by the audit• extent of authority of the auditor

Legal requirements The scope of the audit determines and may be determined byfood safety legislation which may include:

• Food standards code• Relevant state legislation and related codes of practice

including industry sector-specific legislation and relatedcodes of practice such as that relating to meat, seafood,dairy and primary production and processing

• Regulatory and commercial requirements relevant toimporting countries

• Commonwealth legislation (eg. Export Control Act)

Other legislation which may impact on the conduct of a foodsafety auditor may include legislation covering:

• OHS, anti-harassment, anti-discrimination and industrialrelations

• Trade practices legislation• Environmental risk management• Legal contracts or agreements




Audit client The organisation or person requesting an audit (systemowner). This may be the same as the auditee or any otherorganisation which has the regulatory or contractual right torequest an audit.

The system owner may be the regulator.

Auditee The organisation being audited.

Audit client requirements Client requirements are typically defined in audit contracts oragreements and may relate to:

• legal requirements• food safety management system requirements• compliance with client site operational policies and

procedures• confidentiality• business size, activities and processes• business culture• professional standards of conduct

Audit criteria The audit criteria must comply with relevant food safetylegislation and may extend to address additional systemowner/client requirements. In addition to meeting therequirements of food safety legislation, reference against whichconformity is determined may include:

• management systems policies and procedures• industry standards or codes• contractual requirements• international treaties and conventions

Levels of non-conformity Levels of non-conformity are defined and based on food safetyrisk. They may be determined by:

• the management system• the audit client• legislation

Where legislation applies, definitions may be determined by:

• state and territory authorities, and/or• AQIS• Primary industry jurisdiction• Primary food production jurisdiction




Audit evidence Evidence required for the purposes of meeting relevant foodsafety legislation may be defined by the client and/or theregulatory authority.

Audit evidence should be based on objective information ratherthan hearsay and may include:

• system records• evidence collection records• statements of fact or other information relevant to the

audit criteria and which is verifiable• observations• records of audit stage progression.

Evidence collectionmethods and sources

These will depend on the purpose and scope of the audit andmay include:

• observation• interviews• checklists• auditee documentation review• reports/data from other sources such as customer

feedback, technical references, computerised databases• results of analyses.

Food safety managementsystem

Documented arrangement implemented [and resourced] by abusiness for control of food safety. A food safety managementsystem includes commitment from management, proceduresand practices to identify and control food safety hazards andprevent their recurrence. It may incorporate recognised foodsafety tools such as HACCP and its prerequisite programs.

Resource requirements Resource requirements will depend on the purpose and scopeof the audit and may include:

• audit personnel directly involved in undertaking the audit• access to relevant personnel and information within the

business• access to any additional resources as required.

Food businesses A food business refers to a business, vehicle, enterprise oractivity where food is produced, processed, stored, displayed,transported and/or sold. It may also include primary producers

Preliminary work This includes (but is not limited to):

• identifying food to be covered by the food safety program• defining the food and the method of distribution• identifying customers and intended use of food• describing the process (flowchart)• checking for accuracy and completeness of the previous

steps




Audit records Audit records are maintained to demonstrate theimplementation of the audit process. These may include butare not limited to:

• audit plans• audit reports• non-conformity reports• corrective action reports• follow up reports.

Close out Auditors have different levels of responsibility and authority toclose out audits according to the level of non-conformity andwhether they are an authorised officer or a commercial auditor.Closing out may involve notifying the regulator with the powerto enforce legislation.

Commercial auditor This refers to any auditor other than a regulatory auditor, whois external to and independent of the food business beingaudited.

Risk-based approaches Risk-based approaches to controlling food safety are typicallybased on HACCP, described in the Codex Alimentariusguidelines




Pre-requisite programs Pre-requisite programs are also referred to as supportprograms, or acronyms such as Good manufacturing practice(GMP), Good Agricultural Practice (GAP) and Good HygienePractice (GHP).

Pre-requisite programs can be divided into 2 categories.







Critical control point A step at which control can be applied and is essential toprevent or eliminate a food safety hazard or reduce it to anacceptable level

Critical limit Criterion which separates acceptability from unacceptability

EVIDENCE GUIDE


Overview of Assessment • Assessment may occur in a real or simulated auditcontext where the simulated context provides access toan actual medium or high risk food or primary industrybusiness environment.





All elements, performance criteria, and required skills andknowledge are critical and must be assessed. Criticalaspects of assessment must include the following:

• Identify food safety legislation applying to a foodbusiness. Legislative requirements may relate to actual orhypothetical food businesses. A minimum of 2 scenariosmust be covered providing that at least one food businessoperates in a market segment that has to meetcompliance requirements in place of* or in addition to theFood Standards Code. The assessment activity must:• Identify the relevant legislation applying to the food

business taking account of the industry sector, range offood handling activities undertaken and the marketsinto which products and/or services are sold.

• Locate advice on relevant authorities and enforcementagencies in a state or territory and for internationalmarkets as appropriate.

• Explain the legal responsibilities of a given foodbusiness.

*For example, export meat processors must comply with theExport Control Act and the Export Meat Orders.

• Plan and conduct an audit that complies with legal andclient requirements as appropriate. The criteria andevidence requirements may be developed to apply to anactual or hypothetical food business. The assessee mustsubstantiate:• How audit scope and criteria meet legislative and client

requirements.• The evidence required to assess compliance with the

criteria and to support an objective, reliable andconsistent audit outcome.

• Definitions, levels and related reporting ofnon-conformance to comply with legislativerequirements.

• Submit completed audit records for the selected auditincluding the final audit report, non-conformity reports,corrective action reports, follow up reports andsuggestions for improvements to the food safetymanagement system and to the audit process. Theselatter items may be documented in personal notes ratherthan part of the formal audit report according to the auditscope.

• The whole audit process must be witnessed by theassessor.




FDFFSCHZA Identify, evaluate and control food safetyhazards

Unit Descriptor This unit covers the skills and knowledge required to identify, evaluateand control food safety hazards for the purposes of validating specificcontrol measures in a food safety program. Note that auditors may notbe required to validate food safety programs for the purposes of aspecific audit but they must have the skills and knowledge to be able todo so.

This unit is based on and equivalent to the guideline food safety unitGFSCHZA Identify, evaluate and control food safety hazards

Application of the Unit At the time of writing, ISO/CD 22000 Food Safety ManagementSystems - Requirements for Organisations Throughout the FoodChain' was being drafted. This unit is designed to be consistentwith relevant ISO standards. Users should refer to the currentISO standards for further advice.

This unit applies to both regulatory and commercial food safetysystem auditors.

When assessing compliance of food safety programs in amedium or high risk environment the following units must be preor co-assessed with this unit:



When applied to conducting food safety audits which require bothverification and validation of the food safety program, thefollowing units must be pre or co-assessed with this unit:





1. Identify food safetyhazards in a foodbusiness

1.1 Biological food safety hazards that could present a riskin the food at the point of consumption are identified bytype, origin and food association and assessed todetermine risk level and control requirements

1.2 Intrinsic and extrinsic chemical food safety hazards thatcould present a risk in the food at the point of consumptionincluding toxin presence are identified by type, origin andfood association and assessed to determine risk level andcontrol requirements

1.3 Physical food safety hazards that present a risk in foodare identified and assessed to determine controlrequirements




2. Control food safetyhazards in a foodbusiness

2.1 Processing hazards and related control measures andcritical limits, monitoring and recording requirements areestablished and validated to eliminate or reduce foodsafety hazards to acceptable levels

2.2 Food storage and handling requirements necessary toeliminate or reduce food safety hazards are determined

2.3 Personal hygiene practices required to eliminate or reducefood safety hazards are established

2.4 Cleaning and sanitation, housekeeping and pest controlpractices and procedures required to prevent or reducefood safety hazards are established

2.5 Other pre-requisite programs are developed to eliminateor reduce food safety hazards to acceptable levels






Ability to:

1 Interpret and apply relevant legislation, codes of practice and technical standards2 Identify biological, chemical and physical food safety hazards3 Determine critical control points (CCP) and critical limits for identified hazards4 Establish the required procedures, systems and records to monitor critical control points in

order to demonstrate that the CCP is in control5 Specify required corrective actions and corrections to be taken when critical limits are not

achievedKnowledge of:

1 Sources of advice and research on foods, processing methods, production technologiesand associated food safety hazards and control methods

2 Ways in which food can cause illness and injury. This includes a knowledge of incidenceand trends in food borne illness

3 Intrinsic and extrinsic factors that can impact on food safety4 Common biological food safety hazards (including toxin production and spore formation)

and conditions required for survival and growth of each. This includes an understanding ofthe growth rates, transmission routes, likely carriers and threshold levels

5 Sources of information on acceptable (and legal) levels of biological, chemical and physicalcontamination

6 Food supply chains and potential of a breakdown in control at one point to impact otherparts of the chain

7 Survival and growth requirements of biological food safety hazards8 Common allergenic substances as described by the Food Standards Code (and may be

additionally defined by system owners)9 Common control methods necessary to eliminate or reduce the risk of food borne illness to

acceptable levels for each common pathogen. This includes but is not limited tounderstanding of the role of food storage, temperature control, preservation and processmethods, traceability, product shelf life, cleaning and sanitation and pest control

10 Methods to detect and minimise the risk of food contamination by personal carriers(including convalescent and symptomless carriers) and related minimum legal illnessreporting requirements and personal hygiene procedures

11 The role of microbiological sampling, swabbing and testing in assessing the presence ofbiological contamination

12 Methods to determine the appropriateness and effectiveness of control measures andcritical limits. This includes identifying the effect of control measures on the identified foodsafety hazard; method and feasibility of monitoring; the relationship to other controlmeasures and the severity of consequences and required corrective action in the event offailure of control

13 Types and causes of acute and chronic chemical food borne illness14 The food safety and legal impact of chemical contamination including residual agricultural

and environmental chemicals; residual industrial (including cleaning) chemicals; andchemical contamination as a result of packaging methods and materials

15 Physical hazards that pose a food safety risk16 Common control methods to eliminate or reduce the risk of chemical or physical food

borne illness to acceptable levels for each common form of chemical and physical foodsafety hazard. This includes:16.1 chemicals that pose a food safety risk16.2 common food allergens16.3 physical hazards

17 The role and requirements of pre-requisite programs and procedures to eliminate,




prevent or reduce biological, chemical and physical food safety hazards to acceptablelevels

KEY COMPETENCIES







Solving problems -

Using technology -

RANGE STATEMENT


Food safety hazards A food safety hazard is a biological, chemical, or physicalagent in, or condition of, food with the potential to cause anadverse health effect in humans. (Defined in ' Hazard Analysisand Critical Control Point System and Guidelines for itsApplication', Codex Alimentarius Commission).




Biological food safetyhazards

Common biological food safety hazards include (but are notlimited to):

• Salmonella spp• Campylobacter jejuni• Bacillus cereus• Clostridium perfringens• Clostridium botulinum• Cryptosporidium• Pathogenic escherichia coli• Giardia• Listeria moncytogenes• Shigella spp• Staphylococcus aureus• Vibrio parahaemolyticus• Yersinia enterocolitica• Hepatitis A virus• Norwalk virus

Classifications by type of micro-organism include:

• bacteria• viruses• moulds/fungi• parasites• algae

Chemical food safetyhazards

Common origins of chemical contamination may include:

• cleaning chemicals• pesticides• veterinary residues• chemical additives• allergenic substances• toxic metals• nitrites, nitrates and N-nitroso compounds• polychlorinated biphenyls (PCBs)• plasticizers and packaging migration• phytotoxins• zootoxins

Physical food safetyhazards

Physical food safety hazards refer to objects not normallyfound in food which may cause illness or injury to theconsumer.




Acceptable levels Acceptable levels define the level of a particular hazard in theend product that is acceptable to ensure food safety.Acceptable levels are typically defined by:

• the Food Standards Code• Commonwealth, state or territory legislation or codes• industry codes of practice• international protocols (CODEX Alimentarius)• customer food safety requirements (including intended

use)

Pre-requisite programs • Pre-requisite programs are also referred to as supportprograms. Examples include Good manufacturingpractice (GMP), Good Agricultural Practice (GAP) andGood Hygiene Practice (GHP).

• Pre-requisite programs can be divided into 2 categories.







Critical control point • A step at which control can be applied and is essential toprevent or eliminate a food safety hazard or reduce it toan acceptable level.

Critical limit • Criterion which separates acceptability fromunacceptability




Growth requirements • Factors which influence the growth of pathogenicmicro-organisms may include:

• temperature• water activity• gases• pH• time• moisture• nutrients

EVIDENCE GUIDE


Overview of Assessment Assessment may occur in a real or simulated food business contextwhere the simulated context provides access to food safetyprograms for a multi-staged food supply chain which includes thepoint of delivery to the consumer. A food supply chain refers to asequence of stages and operations involved in the production,processing, distribution and handling of food from primary productionto consumption. The selected supply chain must include at least onemedium or high risk business and/or process and provideopportunity to apply a depth and breadth of food safety knowledge.


All elements, performance criteria, and required skills andknowledge are critical and must be assessed. Critical aspectsof assessment must include the following:

• Select a food supply chain and identify:• known biological food safety hazards that could occur

across the chain and could present a risk in food at thepoint of consumption

• likely patterns of growth and transmission from sourceof contamination to onset of consumer symptoms forpathogens likely to occur in the supply chain. Thisincludes an understanding of threshold levels

• sources of chemical and physical contamination thatcould present a food safety risk at the time of foodconsumption, across the chain

• impact and indicators of the presence of biological orchemical food safety hazards throughout the foodchain

• acceptable levels of contamination. These may beestablished by reference to relevant legislation and/orreference to system requirements.

• Select one stage in the food supply chain (which must bea medium or high risk business or process) and establishor validate control measures and verification records andprocedures.




FDFFSCOMA Communicate and negotiate to conduct foodsafety audits

Unit Descriptor This unit covers the interpersonal skills and knowledge required toselect and use appropriate methods of communication and negotiationto support audit processes.

This unit is based on and equivalent to the guideline food safety unitGFSCOMA Communicate and negotiate to conduct food safety audits

Application of the Unit This unit is mandatory for all food safety auditors.



1. Develop a communicationplan to support auditprocesses

1.1 Roles and responsibilities of the auditee are defined andagreed by both parties to address the audit scope

1.2 Roles and responsibilities of all personnel involved in theaudit process are defined, communicated and agreed

1.3 Appropriate communication methods and protocols aredetermined and specific arrangements including reportingrequirements are agreed

1.4 A communication plan is developed to identify thecommunication requirements and responsibilities ofpersonnel involved in the audit process

2. Select and useappropriatecommunication methodsto conduct an audit

2.1 Appropriate communication methods are used to:2.1.1 establish and maintain effective client relationships2.1.2 collect audit evidence2.1.3 provide and present information2.1.4 facilitate meeting processes2.1.5 facilitate issue management and conflict resolution2.1.6 communicate audit findings

2.2 Communication methods are selected to take account ofsystem owner and food business requirements,workplace culture and individual differences

2.3 Information provided by the auditee is interpreted in thecontext of the industry sector, language and culture of thebusiness


FDFFSCOMA Communicate and negotiate to conduct food safety audits


3. Negotiate to achieveagreement on auditoutcomes

3.1 Areas of disagreement over audit outcomes are identifiedand clarified with the auditee

3.2 Understanding is sought on actions to be followed toresolve outstanding issues

3.3 Communication techniques are applied to encourage allrelevant parties to participate and express their views fully

3.4 Auditee views are treated with respect3.5 Options for resolving differences are explored to reach

agreement and meet audit timeline and resourceparameters

3.6 Appropriate issue resolution strategies are explored toincrease the likelihood of agreement on steps required toconclude the audit

3.7 The negotiation process is managed to maintainconstructive client relationships

3.8 Any areas of continuing non-compliance that result fromunresolved differences are reported to system owners andappropriate authorities as required



Ability to:

1 Select, design and use appropriate communication methods and techniques to support theaudit process and the needs of the audience. These may include people at different levelsof the food business with different English language, literacy and technical skill levels

2 Facilitate groups to resolve sensitive and/or conflict-based issues3 Structure and present written and verbal information that is thorough, legible, clear,

accurate and appropriate to the purpose and the audience4 Use information systems, technologies and software to manage security, authorisation and

distribution of audit data and records5 Communicate information in environments where the recipients may be hostile to the

information being presentedKnowledge of:

1 Legislation that impacts on acceptable communication methods and conduct including antidiscrimination, anti-harassment and privacy legislation

2 Vocabulary and terms relevant to audit process. This includes terms and jargon to describefood safety legislation, technical processes and industry standards

3 Confidentiality needs and expectations of food businesses4 Strategies to communicate in culturally diverse environments5 Dynamics of conflict and strategies to manage resolution6 The structure, authority levels and lines of reporting within a food business7 Communication methods relevant to different groups and audiences8 Reporting formats and requirements to meet client and legislative needs




KEY COMPETENCIES







Solving problems -

Using technology -

RANGE STATEMENT


Communication plan A communication plan identifies:

• the type and purpose of information to be providedthrough each stage of the audit process

• audiences for types of information• the form or method of communication (eg written report,

verbal presentation)• when/how often the communication will occur• Reporting procedures and responsibilities. This includes

reporting timelines, formats and procedure for reportingserious/critical food safety hazards

Communication methodsand protocols

Methods of communication may include:

• written presentations and reports• two-way verbal interaction• constructive feedback• active listening• questioning to elicit, confirm and clarity information• interview techniques• facilitation of meetings and group processes• interpreting non-verbal skills and body language

Communication protocols may include:

• confidentiality• objectivity• information access and dissemination• levels of communication/lines or reporting• timeliness of providing information/responding to

information requests




Food businessrequirements

Business requirements may require that communication isconsistent with:

• confidentiality requirements• legal requirements and related policies and procedures

relating to communication requirements• professional codes of conduct/personal attributes of

auditors• information that is accurate, thorough and clearly

presented• resource parameters• organisational structure and delegated levels of authority• existing communication mechanisms and systems used

in the auditee's workplace

Individual differences Individual differences may include but are not limited to:

• age• race• gender• culture• religion• impairment/disability• physical features• educational background• technical skill level• communication styles and skill levels• English language and literacy• any other individual characteristics that may need to be

taken into account in designing communication ascovered by relevant legislation

Issue resolution strategies Issue resolution strategies may include:

• establishing open communication practices to encouragethe trust and engagement of all parties

• designing processes that ensure all parties haveopportunities to fully express their position

• involving personnel with additional expertise - this mayinclude other expertise from the auditing body and/or theregulator

• validating evidence used to support audit findings




EVIDENCE GUIDE


Overview of Assessment Assessment may occur in a real or simulated audit contextwhere the simulated context provides access to aconflict-based context where audit findings are disputed by theauditee. A simulated environment must provide access to atypical range of personnel with typical communication skilllevels found in food businesses and to the roles of personnelinvolved in food safety audit processes.


All elements, performance criteria, and required skills andknowledge are critical and must be assessed. Critical aspectsof assessment must include the following:

Design a communication plan to meet the needs ofstakeholders in an audit process, specifically where a numberof participants have limited English-language and literacy skills

Facilitate and negotiate to seek understanding of auditoutcomes in a conflict-based situation where the outcomes arecontested by the auditee. This component of assessment mustprovide opportunities to select and apply appropriatecommunication methods.




FDFFSHT4A Audit a heat treatment processUnit Descriptor This unit specifies the outcomes required to support a food safety audit

that includes heat treatment processes designed to bring about adefined logarithmic reduction of the target organism to ensure safefood. This may include pasteurised product with a nominatedrefrigerated shelf life and commercially sterile, shelf-stable product.

The unit applies to auditing aspects of the process that directly relate todelivering the prescribed heat treatment. It covers related factors suchas raw materials receival, pre- and post-process storage and packagingmethods and materials only to the extent that impact on or arecontrolled by the heat treatment process.

This unit supports relevant legislation such as food standards containedin the Food Standards Code and industry codes of practice relating tothe validation and verification of a HACCP-based food safety program,and should be read in conjunction with these documents.



Application of the Unit This unit supports the role of a food safety auditor responsible forauditing heat treatment processes. Audit processes wouldtypically occur within the context of auditing a HACCP-based foodsafety program that defines related prerequisite programrequirements.



1. Identify and assess foodsafety hazards and relatedcontrol options for heattreatment processes.

1.1 Microbiological food safety hazards that could present arisk in the food at the point of consumption are identifiedby type, origin and food association level and assessed todetermine the significance of the hazard.

1.2 Heat treatment processes , control requirements andmethods are identified to ensure that finished, heat-treatedproducts meet food safety objectives.

2. Confirm that appropriateevidence supportsvalidation of the heattreatment process.


2.2 Evidence used by the business to validate the process isidentified and assessed to confirm that it is credible andadequate to achieve the food safety objective.


FDFFSHT4A Audit a heat treatment process


3. Confirm verification of thefood safety program for aheat treatment process.










• interpret and apply relevant legislation, standards, codes of practice and technicalspecifications relating to heat treatment of foods

• identify microbiological food safety hazards that can occur in heat-treated food products• inspect heat treatment plant and equipment to confirm that regulatory, industry and

business standards are met• apply principles of heat treatment to assess the suitability of thermal processes and

related packaging and storage to achieve the food safety objective and minimise the riskof post-processing contamination

• review workplace records and other documentation to verify that the food safety programrelating to heat treatment and related processes is being implemented according to theprescribed process

• review evidence used by the business to validate the food safety control process• confirm methods and evidence used to evaluate the capacity of equipment, processing

method and packaging form to deliver heat distribution and heat penetrationrequirements.


• regulations, codes of practice, guidelines, technical specifications and whereappropriate, specific product heat treatment requirements and Australian standardsrelating to heat treatment of foods

• target organisms that can occur in heat-treated foods and related survival and growthcharacteristics

• principles of heat treatment and application of heat-processing methods to product types• criteria used to specify and evaluate heat treatment for each heat processing method• factors that impact on heat distribution and heat penetration according to

heat-processing method• principles of operation of commercial heat-processing equipment, including equipment

features required to meet regulatory requirements and critical factors to be controlled toensure delivery of prescribed heat treatment and related processes

• procedural safeguards used to track processing of product• principles of packaging to form a suitable seal and impact of packaging system and heat

treatment methods and equipment on process effectiveness and packaging integrity• characteristics of raw materials and pre-processing requirements that impact on the

microbiological profile and need to be considered in determining the thermal process• post-processing packaging and handling that impact on the ability to maintain the food

safety objective following thermal processing, and related prerequisite programsrequired to support effectiveness of heat treatment processes

• food safety risks and controls to avoid post-process contamination of heat-treatedproduct

• principles of sampling requirements and test methods to confirm equipment integrity,effectiveness of heat treatment, packaging system and seal integrity andpost-processing conditions to meet regulatory, industry and business standards.




KEY COMPETENCIES







Solving problems -

Using technology -

RANGE STATEMENT


Heat treatment processesmust include:

• retorting systems• pasteurisation systems• aseptic processing and packaging systems• hot fill systems.













Relevant legislation,standards, codes ofpractice and technicalspecifications relating toheat treatmentrequirements may include:


• Validation and Verification of Heat Treatment Equipmentand Processes (ANZDAC - draft)

• international protocols such as Codex Alimentarius Vol1B - 1995 Section 2, Recommended international code ofhygienic practice for low-acid and acidified low-acidcanned foods, CAC/RCP, 23-1979, Rev 2 1993, App III

• Australian Standard for Equipment for the pasteurizationof milk and other liquid dairy products - Continuous-flowsystems (AS 3993:2003)

• AQIS Export Control (Milk and Milk Products) Orders,2005

• code of practice for the manufacture of egg products• state and territory regulations, codes of practice and

guidelines.

Factors that affect heatdistribution and heatpenetration may include:

• raw material characteristics such as:• rheology and density• particulates and position within container• pH• heat treatment method and related equipment - process

holding times and temperatures• heating systems• packaging design.

Commercial heatprocessing equipment mayinclude:

• pre-processing equipment• methods to achieve sterilisation of plant and packaging

material (for aseptic systems)• filling equipment• heat treatment systems using both direct and indirect

heating methods• packaging systems.

Packaging may include: • cans• glass containers• aluminium and plastic semi-rigid and flexible containers• bags• composite packaging• bulk packaging.




Prerequisite programs: • are also referred to as support programs, or acronymssuch as good manufacturing practice (GMP), goodagricultural practice (GAP) and good hygienic practice(GHP)

• can be divided into two categories:• infrastructure and maintenance programs, which may

include:• layout, design, construction and amenities of

buildings and facilities• supplies of air, water, energy and other utilities• equipment, including sanitary design, preventative



• operational prerequisite programs, which may include:• personal hygiene• measures for the prevention of cross-contamination• packaging and labelling procedures• supplier assurance• chemical storage• employee training• document control• internal audit programs• traceability programs• product integrity and security• cold chain management• inspecting and testing regimes, including analytical

and microbiological testing• control of non-conforming product, processes and

recall programs.

Test methods include: • conducting studies of process evaluation• conducting studies of equipment performance.




Additional referencematerial includes:

• US Food and Drug Administration Guide to Inspections ofLow Acid Canned Food Manufacturers, Parts 1, 2 and 3

• US Food and Drug Administration Code of FederalRegulations. Requirements for EstablishmentRegistration, Thermal Process Filling, and GoodManufacturing Practices for Low-Acid Canned Foods andAcidified Foods, Title 21, Vol 2, Pt 113

• Campden & Chorleywood Food Research Association(1997), Guidelines for batch retort systems - Full waterimmersion - Raining/Spray Water - Steam/Air. Guidelineno. 13

• Campden & Chorleywood Food Research Association(1997), Guidelines for performing heat penetration trialsfor establishing thermal processes for batch retortsystems. Guideline no. 16

• Campden & Chorleywood Food Research Association(1997), Guidelines for establishing heat distribution inbatch over-pressure retort systems. Guideline no. 17

• Campden & Chorleywood Food Research Association(2000), Analysis of temperature distribution and heatpenetration data for in-container sterilisation processes.Review no. 22.




EVIDENCE GUIDE



A person who demonstrates competency in this unit must beable to provide evidence that they can verify food safetyprograms involving heat treatment processes for a range offoods, to meet regulatory, industry and business standards.They must also demonstrate capacity to confirm thatappropriate validation has occurred.


• identify product-specific risks and typical processingmethods for a range of products, including sources ofinformation on heat treatment requirements

• participate in audits of HACCP-based food safetyprograms to demonstrate ability and knowledge oftechnical aspects of heat treatment processes.

Assessment must include the demonstration of appropriatemethods, including the use of time temperature indicators(TTIs) to measure the effectiveness of a range of heattreatment. Related processes such as evaluation of rawmaterials, sterilisation of packaging and equipment (relevant toaseptic systems) and post-process handling will be consideredwhere they directly impact on the effectiveness of heattreatment.

Assessment requires participation in at least two audits. Ofthese, at least one audit must be an in-packaging heattreatment process and one must be an out-of-packaging heattreatment process. One of these must be a heat treatmentprocess of a low acid food.

For given scenarios where prescribed processing requirementsare not met, assess adequacy of evidence used to determineresponse procedures.





Competency may be assessed in an actual workplace orsimulated environment that provides access to the requiredresources. At least one of the audit scenarios should beassessed in an actual workplace context.



• food safety plans covering heat treatment processes• food safety-related documentation typical of commercial

manufacturing businesses and used for the purpose ofverification

• evidence and documentation relevant to heat treatmentprocesses that would typically be used by commercialmanufacturing businesses to support validationprocesses

• plant and equipment that would typically be used in acommercial manufacturing business.


The audits conducted for the purpose of assessment must bewitnessed by an auditor competent to audit heat treatmentprocesses.

Assessment methods must satisfy the endorsed AssessmentGuidelines of FDF03 Food Processing Industry TrainingPackage.




FDFFSME4A Audit manufacturing of ready-to-eat meatproducts

Unit Descriptor This unit specifies the outcomes required to support a food safety auditof food safety programs relating to the manufacture of ready-to-eatmeat products.

The unit covers raw materials receival, processing of ready-to-eat meatproducts and post-processing storage and handling of productundertaken by the manufacturer of ready-to-eat meat products.

This unit supports relevant legislation such as food standards containedin the Food Standards Code, Australian standards and industry codesof practice relating to validation and verification of a HACCP-basedfood safety program, and should be read in conjunction with thesedocuments.



Application of the Unit This unit supports the role of a food safety auditor responsible forauditing ready-to-eat meat manufacturing processes. Auditprocesses would typically occur within the context of auditing aHACCP-based food safety program that defines relatedprerequisite program requirements.



1. Identify and assess foodsafety hazards and controloptions for readyto-eatmeat manufacturing andrelated handlingprocesses.

1.1 Microbiological food safety hazards that could presenta risk in ready-to-eat meat products at the point ofconsumption are identified by type, origin and foodassociation and assessed to determine risk level andcontrol requirements.

1.2 Chemical food safety hazards that could present a riskin ready-to-eat meat products at the point of consumption,including toxin presence, are identified by type, origin andfood association and assessed to determine risk level andcontrol requirements.

1.3 Physical food safety hazards that present a risk in foodare identified and assessed to determine controlrequirements.

1.4 Control requirements and methods are identified to ensurethat finished, ready-to-eat meat products meet food safetyobjectives.


FDFFSME4A Audit manufacturing of ready-to-eat meat products


2. Confirm that appropriateevidence supportsvalidation of thereadytoeat meatmanufacturing process.


2.2 Evidence used by the business to validate the process isidentified and assessed to confirm that it is credible andadequate to meet the food safety objective.

3. Verify the food safetyprogram for a readytoeatmeat manufacturingprocess.










• interpret and apply relevant legislation, standards, codes of practice and technicalspecifications relating to the manufacture of ready-to-eat meat products

• identify microbiological, chemical and physical food safety hazards associated with themanufacture of ready-to-eat meat products

• inspect plant and equipment to confirm that regulatory, industry and business standardsare met

• apply principles of ready-to-eat meat manufacturing to assess the suitability ofprocesses to ensure a safe finished product

• review workplace records and other documentation to verify that the HACCP-based foodsafety program relating to the meat product being manufactured is being implementedeffectively

• review evidence used to validate the food safety control process.


• regulations, codes of practice, guidelines, technical specifications and Australianstandards relating to the formulation and manufacture of ready-to-eat meat products

• sources of information on acceptable processing and related storage and handlingmethods and parameters for given products and target micro-organisms

• pathogens that can occur in meat products and related control methods required inmanufacturing, post-processing and storage

• survival and growth characteristics of pathogens and ability of processed product tosupport pathogen growth

• chemicals that pose a food safety risk in meat products and related control methods• physical sources of contamination and related control methods• effect of raw material characteristics such as bacterial load and temperature, and

pre-processing conditions on the growth of pathogens• prerequisite programs required to support safe manufacture of ready-to-eat meat

products• purpose, role and storage requirements of ingredients• principles of manufacturing methods and factors that affect processing requirements• use and effectiveness of hurdle technologies• principles of packaging to form a suitable seal and requirements of post-processing

handling and conditions to ensure safe product• principles of operation of ready-to-eat meat product manufacturing equipment, including

equipment features required to meet regulatory requirements and critical factors to becontrolled to ensure safe food outcomes

• indications of unacceptable product and related test requirements• principles of test methods and frequency in monitoring condition of raw materials and

processing, and in confirming that final product is fit for human consumption.




KEY COMPETENCIES







Solving problems -

Using technology -




RANGE STATEMENT


Prerequisite programs: • are also referred to as support programs or such thingsas good manufacturing practice (GMP), good agriculturalpractice (GAP) and good hygienic practice (GHP)

• can be divided into two categories:• infrastructure and maintenance programs, which may

include:• layout, design and construction of buildings and

facilities• supplies of air, water, energy and other utilities• equipment, including sanitary design, preventative

maintenance, calibration and cleaning and sanitation• support services, including waste and sewage disposal• pest control

• operational prerequisite programs, which may include:• personal hygiene• measures for the prevention of cross-contamination• packaging and labelling procedures• supplier assurance• chemical storage• employee training• document control• internal audit programs• traceability and recall programs• product integrity and security• cold chain management• preparation, maintenance and use of starter cultures

(for fermented meat products)• inspecting and testing regimes, including analytical and

microbiological testing• control of non-conforming product, processes and

facilities• animal welfare.

Manufacturing and relatedhandling and storageprocesses to control foodsafety include:

• heat treatment• fermentation and maturation• use of starter cultures• drying• cold storage• salting and other water activity related controls, e.g. hot

smoking• chemical additives to control water activity, pH and/or

preservation, e.g. glucono-delta-lactone (GdL) and liquidsmoke.




Microbiological food safetyhazards that commonlyoccur in ready-to-eat meatsinclude:

• bacteria• Campylobacter jejuni (poultry)• pathogenic Escherichia coli, including

enterohaemorrhagic Escherichia coli• Clostridium perfringens and C. botulinum• Listeria monocytogenes• Salmonella spp• Staphylococcus aureus• Yersinia enterocolitica

• viruses• moulds and fungi• parasites• algae.

Ready-to-eat meatproducts refer to meatproducts intended to beconsumed without furtherheating or cooking andinclude:

• cooked, heat-treated or uncooked fermented meat,including cooked fermented meats (CFM), uncookedcomminuted fermented meat (UCFM) and othersalami-type products

• pate• dried meat• slow cured meat• luncheon sausage meat, including processed and

manufactured• cooked muscle meat, including ham and roast beef• other ready-to-eat meat that is susceptible to the growth

of pathogens or the production of toxins.

Chemical food safetyhazards include:

• cleaning chemicals• pesticides• veterinary residues• chemical additives and levels• allergenic substances• toxic metals• nitrites, nitrates and N-nitroso compounds and levels• polychlorinated biphenyls (PCBs)• plasticisers and packaging migration.

Physical food safetyhazards refer to:

• objects not normally found in food that may cause illnessor injury to the consumer, such as fragments of:• bone• glass• metal• plastic• wood.






• the application of:• existing Australian legislative requirements• challenge tests• peer-reviewed scientific papers• targeted scientific reports• validation already carried out in other jurisdictions and





Equipment may include: • fermentation rooms• filling machines• drying and maturation rooms• mixers and blenders• tumblers• cookers• injectors• mincing machines and slicers or dice machines• conveyors• packaging machines• cooking utensils and knives• equipment used for the purpose of conducting analytical

tests.



Relevant legislation,standards, codes of practiceand technical specificationsrelating to requirements ofready-to-eat meatmanufacture may include:


• relevant Australian standards, including the AustralianStandard for the Hygienic Production and Transportationof Meat and Meat Products for Human Consumption (AS4696:2002)

• Australia Export Control Act, 1982• AQIS Export Control (Meat and Meat Products) Orders,

2005• international protocols such as those of the Codex

Alimentarius Commission• customer food safety requirements, including intended

use• state or territory regulations, codes of practice and

guidelines.




Hurdle technologies refer to: • the application of a combination of different processingmethods or techniques or treatments to achieve safe foodoutcomes.

Test methods includemethods used to measure:

• E. coli, Salmonella, coagulase positive staphylococci,Listeria monocytogenes in raw materials and final product

• pH• time and temperature of:

• fermentation• maturation or drying• smoking• cooking or heating

• weight loss or water activity.

Packaging refers to: • controlled atmosphere (CA) packaging• modified atmosphere (MA) packaging.

Ingredients must comply withthe requirements describedin the Food Standards Codeand may include:

• raw materials (meat)• starter cultures• preservatives, e.g. sodium chloride and sulphites• water• sodium and potassium nitrate and/or nitrite• nitrate• spices• binders• water and ice• phosphates and other additives.

Additional reference materialincludes:

• guidelines for safe manufacture of smallgoods, Meat andLivestock Australia Ltd, September 2003.




EVIDENCE GUIDE



A person who demonstrates competency in this unit must beable to provide evidence that they can verify manufacturingprocesses for a range of ready-to-eat meat products to meetregulatory, industry and business standards. They must alsodemonstrate capacity to confirm that appropriate validation hasoccurred.


• identify product-specific risks and typical processingmethods, including sources of information on processingparameters, for a range of products

• participate in audits of HACCP-based food safetyprograms to demonstrate ability and knowledge oftechnical aspects of the manufacture, storage andtransport of safe ready-to-eat meat products - auditscenarios must include at least one product in each of thefollowing product categories:• uncooked fermented meat products, such as salami• smoked or cooked meat products, such as ham• slowly cured meat, such as prosciutto• pate.

Cold ready-to-eat meat products may also have undergonefurther processing stages including slicing, shaving andpackaging

Audits of product type may be conducted concurrently orseparately, according to production environment.


Competency may be assessed in an actual workplace orsimulated environment that provides access to the requiredresources.



• relevant plant and equipment that would typically be usedin the commercial manufacture of ready-to-eat meatproducts

• food safety programs and related documentation• records for the purpose of verification• evidence to support validation.





The audits conducted for the purpose of assessment must bewitnessed by an auditor competent to audit the manufacture ofready-to-eat meat.

Assessment methods must satisfy the endorsed AssessmentGuidelines of FDF03 Food Processing Industry Training Package.




FDFOPTAP3A Participate in an audit processUnit Descriptor This is an Optional unit. Participation implies that the person can

participate in all stages of an audit but is not responsible for negotiatingaudit scope, allocating audit tasks to others or reporting on auditoutcomes.

This covers the skills and knowledge required to participate in aninternal audit process. This unit is appropriate where internal auditprocesses are conducted to support externally audited programs.Auditing must occur in an area that the person is not directlyresponsible for and where they are required to follow a formal,structured process. It is designed to support participation in auditing arange of programs designed to identify hazards, assess risk andimplement control measures. These may include but are not limited tofood safety, health and safety, quality and environmental management.At this level, the person would typically work under direction and maybe required to operate within established audit procedures such asthose outlined in ISO 10011.

This unit is based on and achieves part of the guideline food safety unitGFSCFSAA Conduct food safety audits.



1. Participate in planning anaudit

1.1 Roles and responsibilities for participating in the audit areidentified

1.2 The purpose and scope of the audit is identified1.3 Information and resources required to conduct the audit

are identified and located

2. Participate in conductingan audit

2.1 Information is collected that is adequate, representativeand meets audit requirements

2.2 Information is analysed to assess adequacy ofperformance against program

2.3 Records are reviewed to confirm compliance with theprogram

2.4 Compliance with the program is observed in the workplace2.5 Areas requiring corrective action are identified

3. Report and follow up auditoutcomes

3.1 Situations presenting an imminent and serious risk to theprogram objectives are identified and reportedimmediately in accordance with reporting requirements

3.2 Audit reports are prepared to address audit scoperequirements

3.3 The results of the audit are communicated according toaudit purpose and requirements

3.4 A corrective action plan is developed


FDFOPTAP3A Participate in an audit process


KEY COMPETENCIES







Solving problems -

Using technology -

RANGE STATEMENT


Range description • Audits may be conducted against workplace programsand/or legislative requirements

• Audits may be undertaken for advisory or regulatorypurposes and may be led by internal or external auditors

• Information collection methods include interviews,observance, review of workplace records and accessingrelevant technical information

• A corrective action plan identifies non-conformance,corrective actions, date by which action must be takenand any other follow up requirements




EVIDENCE GUIDE


Ability to: • Identify personal roles and responsibilities forparticipating in the audit process

• Identify audit purpose, scope, steps and timelines• Identify and locate information required to conduct the

audit• Review workplace documentation to confirm that required

information is available• Prepare tools as required to collect information. These

typically include checklists and interview schedules• Identify any changes that have occurred in the workplace

since initiating the program or since the last programaudit that could affect program outcomes

• Apply appropriate questioning, observation and relatedcommunication skills to support information collection

• Review records, conduct interviews, observe workplacepractice and collect other relevant information as requiredto assess compliance with program requirements

• Take immediate action to report non-conformities thatpresent an imminent and serious risk to the programobjectives within level of responsibility

• Identify, investigate and record evidence ofnon-conformance and judge significance

• Assess the adequacy of the program by analysing theinformation collected against the program objectives

• Form conclusions on audit outcomes based on anobjective assessment of evidence collected

• Report the findings of the audit in appropriate format• Communicate audit outcomes within level of responsibility

using techniques and presentation styles appropriate tothe audience

• Where findings indicate either a failure to comply with theprogram or inadequacy of the program, participate ininvestigation of causes of failure and identification ofcorrective action options




Knowledge of: • The purpose and intent of the program being audited• Personal roles and responsibilities in the audit process

and related responsibilities of other members of the auditteam

• The purpose and stages involved in the audit process• Workplace information and related information

management systems• Techniques for collecting information. This includes

awareness of options, relevance and strengths andweaknesses of each method to ensure data is adequateand representative

• Data analysis methods relevant to the audit process• Communication skills and techniques appropriate to the

workplace• Technical knowledge relevant to the program being

audited in order to verify compliance and assessadequacy of existing control measures. This includesawareness of relevant industry standards

• Purpose and responsibilities for maintaining records


Pre-requisite units

The pre-requisite/s for this unit are the relevantprogram-related unit/s. These may include:

• FDFCORFSY2A Implement the food safety program andprocedures

• FDFCORHS2A Implement occupational health and safetysystems and procedures

• FDFCORQAS2A Implement quality systems andprocedures

• FDFOPTENV2A Implement environmental policies andprocedures


This unit should be assessed together with core units and otherunits of competence relevant to the function or work role. Inaddition, the following optional unit may be relevant:

BSBCMN405A Analyse and present research information



• Workplace program documentation• Audit procedures and standards as applied in the

workplace• Advice on related legislation, industry standards and

codes of practice• Information systems and data collection technology• Reporting formats/requirements• Workplace/personnel access as required to collect

data/observe compliance




FDFPHCCP4A Participate in change control proceduresUnit Descriptor This unit provides an overview of the change management and

validation procedures that form part of GMP.Application of the Unit This unit applies to people working in supervisory or line

management production/packaging roles. This person wouldtypically work within defined change management and validationprograms and procedures. They contribute to the development ofthese procedures as a team member and are responsible toensure procedures are supported in the work area.



1. Participate in planningchange

1.1 Regulations, codes and guides relevant to the workarea are identified

1.2 Procedures, roles and responsibilities for managingchange are identified

1.3 Risk assessment is conducted1.4 Planning of change management is undertaken within

level of responsibility1.5 Workplace documentation affected by the change is

identified and responsibilities for review are allocatedwithin level of responsibility

1.6 Any training needs arising from change are identified anddelivery method/s and responsibilities are determined

1.7 Validation and/or other relevant authorisationrequirements and procedures are identified and followed

2. Participate inimplementing change

2.1 Change is implemented according to the changemanagement plan and OHS procedures

2.2 Advice on change is communicated to all affectedpersonnel

2.3 Relevant training is sourced2.4 Workplace documentation is revised to reflect change

requirements2.5 Change is monitored and evaluated against established

evaluation criteria2.6 Any further adjustments or modifications are identified and

implemented or reported according to change controlprocedure

2.7 Outcomes are documented and reported to meet changecontrol requirements


FDFPHCCP4A Participate in change control procedures




Ability to:

• Locate regulations, codes, guides and internal company documentation relevant to GMPand products/processes used in the work area

• Participate in change control procedures• Apply communication and consultation skills to engage and consult with work areas and

personnel affected by change• Ensure that related skills and knowledge requirements are addressed by the training

system• Apply negotiation/issue resolution skills• Prepare workplace documentation in plain English and suited to purpose and audience

Knowledge of:

• Types of change that come within the scope of change control procedures• Change classification procedures and responsibilities• Principles of risk management and related procedures• Documentary evidence required to support change request• Change control procedures, roles and responsibilities• Workplace documentation including procedures for review, authorisation and control of

documents• Training system including assessment methods and documentation• Validation system, procedures and responsibilities

KEY COMPETENCIES







Solving problems -

Using technology -




RANGE STATEMENT


Regulations, codes andguides

• Relevant regulations, codes and guides include:• Therapeutic Goods Act• Therapeutic Goods Regulations• Australian Code of Good Manufacturing Practice for

Medicinal Products• TGA guides to interpretation of legal requirements• regulations, codes and guides related to other relevant

international legislation (appropriate to product andmarket)

• company policies and guidelines

Change Change that must be controlled refers to any change that mayaffect product quality or reproducibility of the process. This mayinclude but is not limited to change in:

• formulation• product component• method of production or testing• process environment (or site)• batch size• equipment

Change management Change management procedures and data requirements mustmeet the requirements of Change Management as outlined inAnnex 15 of the Australian Code of Good ManufacturingPractice for Medicinal Products

Workplace documentation Workplace documentation relevant to work area activitiesincludes:

• company policies and procedures• specifications• manufacturing formulae• processing and packaging instructions• scaling batch size up or down• batch production and packaging records• Standard Operating Procedures (SOPs)• operating manuals• OHS information including Material Safety Data Sheets

(MSDS)

Authorisation requirements Authorisation requirements reflect regulatory requirements andinternal authorisation processes




Change management plan A change management plan includes steps or activitiesrequired to approve and implement the proposed change.Typically these steps will be described in a change controlSOP. Depending on the significance/level of the change, thiscould include:

• process capability assessment• test methods• validation• liaison with regulator• It also includes:• timelines• responsibilities including sign-off/approval• verification of the effectiveness of change• OHS implications

EVIDENCE GUIDE


Overview of assessment Assessment may occur in a real or simulated pharmaceuticalor complementary medicine manufacturing workplace wherethe assessment environment provides access to workplacedocumentation and document management systems related tochange control that are typical of commercial manufacturingbusinesses and meet the requirements of the TherapeuticGoods Act. It will also provide a range of commercialmanufacturing packaging equipment and activities typicallyused in a commercial manufacturing environment.

Resources for assessment Change request.

Workplace documentation including procedures relating tochange control.

Real or simulated workplace context.




Overlap with related units This unit could be assessed concurrently with other unitsrelating to problem solving and process improvement. Thismay include:

FDFPHGMP4A Facilitate and monitor Good ManufacturingPractice

FDFPHVP4A 4 Participate in validation processes

FDFPHFCC4A Facilitate contamination control

FDFPHRWD4A Prepare and review workplace documentationto support GMP

MCMT450A Undertake process capability improvements

FDFOPTSPC2A Apply principles of statistical process control

Method of assessment Assessors must be satisfied that the person canconsistently perform the unit as a whole, including allelements, performance criteria, and required skills andknowledge. A holistic approach should be taken to theassessment.

Assessment of this unit would typically involve responding to'what if' scenarios, answering questions and conductingworkplace projects.


Evidence of participation in a project team to control change ina work area. This includes providing evidence that thecandidate:

• Can identify situations requiring change control for agiven set of change scenarios.

• Participates in developing a change management plan.• Develops a documented implementation plan to introduce

change into a work area. This may be a sub-set of alarger change management plan.

• Leads the implementation of change in a work area. Thisincludes reviewing relevant workplace documentation,ensuring that required training occurs, consulting withparties affected by change and negotiating any issuesraised, monitoring and reporting on change and liaisingwith relevant departments/ personnel to ensure thatauthorisation and validation processes occur as required.




FDFPHCON2A Operate a concentration processUnit Descriptor This is a specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down processes used to concentrateliquid products.

Application of the Unit This unit applies to production operators working in thepharmaceutical sector. This person would typically work withindefined GMP programs and procedures.



1. Prepare the concentrationequipment and processfor operation

1.1 Materials and services are confirmed to meet productionrequirements

1.2 Workplace documentation relevant to work areaactivities is identified and followed

1.3 The required facilities, storage, equipment and personnelare available

1.4 Line clearance procedures have been carried out1.5 Procedures to eliminate or control the risk of

cross-contamination are followed1.6 The concentration process is set up and started up in

accordance with workplace practices

2. Operate and monitor theconcentration process

2.1 The concentration process is monitored to confirm thatspecifications are met

2.2 Out-of-specification product/process is identified, rectifiedand/or reported to maintain the process withinspecification

2.3 The workplace is maintained in accordance withhousekeeping standards

2.4 Workplace documentation is maintained according toworkplace reporting requirements

3. Shut down theconcentration process

3.1 The process is shut down according to workplaceprocedures and practices



FDFPHCON2A Operate a concentration process




Ability to:

• Select, fit and use personal protective clothing and/or equipment• Conduct pre-start checks. This may involve inspecting equipment condition to identify

any signs of wear; confirming that equipment is clean and correctly configured forprocessing requirements; checking that sensors and controls are correctly positioned,and any scheduled maintenance has been carried out. It may also include turning on oilpumps to the evaporator, and pre-running equipment in line with operating temperaturerequirements

• Start, operate, monitor and adjust process to achieve required outcomes. This mayinclude monitoring control points and conducting inspections as required to confirmprocess remains within specification. This may include monitoring:• product and machine temperature• vacuum• distillate colour• viscosity of concentrate

• Take corrective action in response to out-of-specification results• Respond to and/or report equipment failure within level of responsibility• Demonstrate batch/product changeovers including line clearance procedures• Clean and sanitise equipment as required• Sort, collect, treat, recycle or dispose of waste• Complete workplace records as required• Maintain work area to meet housekeeping standards

Knowledge of:

• Purpose and principles of each stage of the concentration process. This includes anunderstanding of the effect of heat and vacuum on distillate volume

• Basic operating principles of the equipment. This includes an operational understandingof the main equipment components and equipment operating capacities andapplications. It also includes knowledge of services required and action to take ifservices are not available

• Quality requirements of materials and the effect of variation on the concentrationprocess

• Process specifications, procedures and operating parameters for differentproducts/materials

• Operating requirements and parameters and corrective action required where operationis outside specified operating parameters

• Typical equipment faults and related causes. This includes recognition of signs andsymptoms of faulty equipment and early warning signs of potential problems

• Methods used to monitor the concentration process. This may include inspecting,measuring and testing as required by the process. It includes an ability to calculateyields, and the ability to determine the number of passes required to ensureconcentration is within specification

• Contamination/food safety risks associated with the concentration process• Common causes of variation and corrective action required• OHS hazards and controls. This includes an awareness of the risks involved with the

use of solvents such as ethanol, and the limitations of protective clothing and equipmentused

• Concentration process shut down procedures and responsibilities• Line clearance procedures. This includes procedures for cleaning feed lines• Environmental issues and controls relevant to the concentration process. This includes




waste collection and handling procedures related to the process• Cleaning and sanitising procedures• Workplace documentation and authorisation procedures

KEY COMPETENCIES







Solving problems -

Using technology -

RANGE STATEMENT


Materials Materials include feed liquor/liquids products, ethanol, distillateand water

Workplace documentation Workplace documentation relevant to work area activitiesinclude:

• specifications• manufacturing formulae• processing instructions• batch production records• Standard Operating Procedures (SOPs)• OHS information including Material Safety Data Sheets

(MSDS)

Equipment Equipment may include centrifugal evaporator and collectingvessels. The evaporator may or may not be in line with heatexchanger. Service equipment also includes boilers andcooling towers




Work practices Work is carried out according to:

• company policies and procedures• legislative and licensing requirements. This includes

therapeutic good legislation, weights and measures andlegislation relating to OHS, environmental management,equal opportunity and affirmative action, industrial awardsand agreements

Clean and sanitiseequipment

Cleaning and sanitation procedures may include CIPprocedures for cleaning equipment, involving cleaning withremaining distillate, rinsing with water, caustic cleaning andrinsing with water till machine is neutralised

EVIDENCE GUIDE


Overview of assessment Assessment may occur in a real or simulated workplace.Where a simulated environment is used, it should provideaccess to workplace documentation, plus liquid extracts to beconcentrated, concentration equipment and services.

Resources for assessment Workplace documentation relating to concentration processand procedures.



Assessment of this unit would typically involve observation ofthe operator preparing, operating and shutting down theconcentration process to meet production requirements.Observation should be sufficient to confirm consistentperformance.


This includes providing evidence that the candidate:

• Prepares the concentration process for operation -including following line clearance procedures.

• Starts up, operates and monitors equipment to produceconcentrate within specifications.

• Maintains all necessary records.




FDFPHEXT2A Operate an extraction processUnit Descriptor This is a specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down processes used to extractphytochemicals from plant material using solvents.




1. Prepare the extractionequipment and processfor operation

1.1 Materials are confirmed, blended and prepared to meetproduction requirements




cross-contamination are followed1.6 Material is loaded into percolator and solvent/s are added

to specification

2. Operate and monitor theextraction process

2.1 The extraction process is monitored to confirm thatspecifications are met


2.3 The workplace is maintained in accordance withhousekeeping standards

2.4 Workplace documentation is maintained according toworkplace reporting requirements

3. Shut down the extractionprocess

3.1 The process is shut down according to workplaceprocedures and work practices



FDFPHEXT2A Operate an extraction process




Ability to:


any signs of wear; confirming that equipment is clean and correctly configured forprocessing requirements; checking that sensors and controls are correctly positioned,and any scheduled maintenance has been carried out. It may also include the placementof sand filters/scourers in base of percolators

• Start, operate, monitor and adjust process to achieve required outcomes. This mayinclude monitoring control points and conducting inspections as required to confirmprocess remains within specification. This may include monitoring:• density of herbs in percolator - including re-packing of percolator as required• rate/amount of solvent addition• extract collection and yield

• Take corrective action in response to out-of-specification results• Respond to and/or report equipment failure within level of responsibility• Demonstrate batch/product changeovers including line clearance procedures• Sort, collect, treat, recycle or dispose of waste• Clean and sanitise equipment as required as required• Complete workplace records as required• Maintain work area to meet housekeeping standards

Knowledge of:

• Purpose and principles of each stage of the extraction process. This includes anunderstanding of the effect of herb density on filtration and packing process required fordifferent types of herbs

• Basic operating principles of the equipment. This includes an operational understandingof the main equipment components and equipment operating capacities and applications

• Quality requirements of materials and the effect of variation on the extraction process• Process specifications, procedures and operating parameters for different

products/materials• Operating requirements and parameters and corrective action required where operation

is outside specified operating parameters• Typical equipment faults and related causes. This includes recognition of signs and

symptoms of faulty equipment and early warning signs of potential problems• Methods used to monitor the extraction process. This may include inspecting, measuring

and testing as required by the process. It includes an ability to calculate yields• Contamination/food safety risks associated with the extraction process• Common causes of variation and corrective action required• OHS hazards and controls. This includes an awareness of the risks involved with the


• Extraction process shut down and changeover procedures and responsibilities• Environmental issues and controls relevant to the extraction process. This includes

waste collection and handling procedures related to the process• Cleaning and sanitising procedures• Workplace documentation and authorisation procedures




KEY COMPETENCIES







Solving problems -

Using technology -

RANGE STATEMENT


Materials Materials include dried or fresh herbs. Material may be pre-processed (milled), weighed and blended prior to extractionprocess



(MSDS)

Equipment Equipment may include blenders/mixers, percolators, tampingrods, and collection vessels

Extraction process Solvents used in the extraction process may be either aqueousand/or alcohol based. Temperature may or may not be appliedduring extraction process







EVIDENCE GUIDE


Overview of assessment Assessment may occur in a real or simulated workplacecontext. Where a simulated environment is used, it shouldprovide access to workplace documentation, and a typicalrange of extraction solvents, material and equipment.

Resources for assessment Workplace documentation relating to extraction process andprocedures.



Assessment of this unit would typically involve observation ofthe operator preparing, operating and shutting down theextraction process to meet production requirements.Observation should be sufficient to confirm consistentperformance.



• Prepares the extraction process for operation - includingfollowing line clearance procedures.

• Loads materials and solvents to maximise extractcollection.

• Monitors the extraction process.• Maintains all necessary records.




FDFPHFCC4A Facilitate contamination controlUnit Descriptor This unit provides an overview of the cleaning and sanitation systems,

equipment and procedures used in a pharmaceutical workplace. Itcovers the skills and knowledge required to facilitate contaminationcontrol in a work area.

Application of the Unit This unit applies to people working in supervisory or linemanagement production/packaging roles. This person wouldtypically work within defined cleaning, sanitation, change controland validation programs and procedures. They need to be awareof the systems, equipment and procedures used and areresponsible to oversee implementation in their work area.



1. Contamination risks andrelated control measuresare identified andimplemented to meetGMP requirements

1.1 Hazards that could present a contamination risk areidentified by type, origin and product association

1.2 Hazards and related control measures, critical limits,monitoring and recording requirements are reviewed andmeet GMP requirements

1.3 Control measures are verified or validated

2. Review systems andprocedures used tocontrol risk of crosscontamination

2.1 Effective barriers and control systems to minimise riskof cross contamination are identified and meet GMPrequirements

2.2 In-process and environmental monitoring occurs and isrecorded as required by GMP

2.3 Cleaning procedures are validated according to validationprocedures, roles and responsibilities

2.4 Line clearance checklists and procedures are followed inthe work area

2.5 Personal hygiene and conduct of personnel in the workarea meets GMP requirements

2.6 Operators have the required skills and knowledge requiredto support cleaning and sanitation and personal hygienepolicies and procedures






Ability to:

• Interpret and apply relevant legislation, codes, guidelines and technical standards• Use management systems to ensure that procedures are understood and implemented• Monitor that data is recorded to meet GMP recording requirements• Read and interpret equipment drawings, P&IDs (piping and instrumentation diagrams)

and process flow charting• Read and interpret typical test results for in-process and environmental monitoring• Use communication and document management systems to access and review relevant

documents

Knowledge of:

• Principles of workflow design to minimise risk of contamination• Facility and segregation requirements relevant to products produced• Basic microbiology• Micro-biological limits, monitoring methods and reporting and recording formats and

requirements• Sources of technical advice• Ventilation system requirements• Personal hygiene and clothing requirements including decontamination and laundering• Cleaning records and logs• Line clearance procedures, roles and responsibilities• Equipment status labelling• Cleaning requirements and levels related to dedicated production, campaign processing

and multiple product processing• Storage requirements including storage requirements of raw materials prior to use in

manufacture, time limits and conditions of storage of finished product prior to packaging,and other requirements relevant to product range

KEY COMPETENCIES







Solving problems -

Using technology -




RANGE STATEMENT


Barriers and controlsystems

Barriers and control systems include but are not limited to:

• ventilation systems• appropriate clothing• area access restrictions and procedures• cleaning and sanitation procedures• environmental monitoring• line clearance checklists• personal hygiene and conduct• pest prevention• Refer to the Australian Code of Good Manufacturing

Practice for Medicinal Products

Codes, guidelines andtechnical standards

This includes the Australian Code of Good ManufacturingPractice for Medicinal Products, Chapter 3 which outlinesminimum requirements for design of pharmaceutical productionfacilities and equipment

Basic microbiology Basic microbiology covers the ability to source information on:

• likely microbiological contaminants givenproduct/packaging used

• origins• growth rates• transmission routes• likely carriers• control limits• control methods

Sources of technicaladvice

Sources of technical advice include but are not limited to:

• Therapeutic Goods Administration• British Pharmacopeia• European Pharmacopeia• US Pharmacopeia

Storage requirements Storage requirements may include but are not limited to:

• storage requirements of raw materials prior to use inmanufacture

• time limits and storage conditions for finished productprior to packaging

• other requirements relevant to product range




EVIDENCE GUIDE


Overview of assessment Assessment may occur in a real or simulated pharmaceuticalor complementary medicine manufacturing workplace wherethe assessment environment provides access to workplacedocumentation and document management systems related tocontrolling contamination that are typical of commercialmanufacturing businesses and meet the requirements of theTherapeutic Goods Act. It will also provide a range ofcommercial manufacturing packaging equipment and activitiestypically used in a commercial manufacturing environment.

Resources for assessment Copies of the relevant Act, regulations, codes and guides.

Workplace documentation relating to cleaning and sanitation.





FDFPHVP4A Participate in validation processes










Evidence must confirm that the candidate has:

• Identified legal, company and audit requirements ofcontamination control systems and conducted a systemreview to support audit readiness.

• Demonstrated methods used to monitor consistentobservance of contamination control.




FDFPHFIL2A Operate a filtration process usingdiatomaceous earth

Unit Descriptor This is a specialist unit. It covers the skills and knowledge required toset up, operate, adjust and shut down filtration equipment used toseparate microbial and particulate matter from liquid extracts.




1. Prepare the filtrationequipment and processfor operation

1.1 Materials are confirmed and available to meet productionrequirements





cross-contamination are followed1.7 Pads and frames are prepared and assembled to meet

operating requirements1.8 Pre-start checks are carried out as required by workplace

requirements

2. Operate and monitor thefiltration process


2.2 The filtration process is monitored to confirm thatspecifications are met


2.4 Separation of solids from solution meets specifications2.5 The workplace is maintained in accordance with

housekeeping standards2.6 Workplace documentation is maintained according to

workplace reporting requirements

3. Shut down the filtrationprocess




FDFPHFIL2A Operate a filtration process using diatomaceous earth




Ability to:


any signs of wear; confirming that equipment is clean and correctly configured forprocessing requirements; checking that sensors and controls are correctly positioned,and any scheduled maintenance has been carried out. It may also involved checkingthat correct pads/frames have been selected and assembled in correct formation; sealsare secure and free of leaks; and pads are pre-soaked and coated in cellite

• Start, operate, monitor and adjust process to achieve required outcomes. This mayinclude monitoring control points and conducting inspections as required to confirmprocess remains within specification. This may include monitoring:• operating pressure of filter press• sound• seals for breakage or leakage• colour of filtered product• flow rates and volume of filtered product

• Take corrective action in response to out-of-specification results• Respond to and/or report equipment failure within level of responsibility• Demonstrate batch/product changeovers and line clearance procedures• Clean and sanitise equipment as required• Sort, collect, treat, recycle or dispose of waste• Complete workplace records as required• Maintain work area to meet housekeeping standards

Knowledge of:

• Purpose and principles of each stage of the filtration process. This includes anunderstanding of the effect of filtration on product colour, microbial and particulate levels

• Basic operating principles of the equipment. This includes an operational understandingof the main equipment components and equipment operating capacities andapplications. It also includes knowledge of services required and action to take ifservices are not available

• Quality requirements of materials and the effect of variation on the filtration process• Process specifications, procedures and operating parameters for different

products/materials• Operating requirements and parameters and corrective action required where operation


symptoms of faulty equipment and early warning signs of potential problems• Methods used to monitor the filtration process. This may include inspecting, measuring

and testing as required by the process. It includes an ability to calculate yields and meettargets

• Contamination/food safety risks associated with the filtration process• Common causes of variation and corrective action required• OHS hazards and controls. This includes an awareness of the risks involved with the


• Filtration process shut down including line clearance processes and procedures• Environmental issues and controls relevant to the filtration process. This includes waste

collection and handling procedures related to the process• Cleaning and sanitising procedures




• Workplace documentation and authorisation procedures

KEY COMPETENCIES







Solving problems -

Using technology -

RANGE STATEMENT


Materials Materials include liquid extract, ethanol, filter aids such asdiatomaceous earth, pre-wetting solutions



(MSDS)

Equipment Equipment may include filter pressing equipment (filter padsand frames), pumping equipment, and collection vessels







EVIDENCE GUIDE


Overview of assessment Assessment may occur in a real or simulated workplacecontext. Where a simulated environment is used, it shouldprovide access to workplace documentation, together with atypical range of filtration, materials and equipment.

Resources for assessment Workplace documentation relating to filtration process andprocedures.



Assessment of this unit would typically involve observation ofthe operator preparing, operating and shutting down thefiltration process to meet production requirements. Observationshould be sufficient to confirm consistent performance.



• Prepares the filtration process for operation - includingfollowing line clearance procedures.

• Starts up, operates and monitors filtration equipment toproduce product within specifications.






Unit Descriptor This unit provides an overview of the systems that support GMP in apharmaceutical workplace and covers the skills and knowledgerequired to facilitate and monitor GMP in a production/packaging workarea.

Application of the Unit This unit applies to people working in supervisory or linemanagement production/packaging roles. This person wouldtypically work within defined GMP programs and procedures.They contribute to the development of these programs as a teammember and are responsible to oversee implementation in theirwork area.



1. Prepare to meet GMPrequirements in the workarea

1.1 Regulations, codes and guides relevant to the workarea are identified

1.2 Workplace documentation relevant to work areaactivities is identified and reviewed to confirm that GMPrequirements are met

1.3 The required facilities, materials, storage, equipment andpersonnel are available

1.4 Operators have the required competence to performproduction/packaging activities to company and GMPstandards

1.5 Line clearance procedures have been carried out1.6 Critical processes have been validated according to

validation requirements1.7 Procedures to eliminate or control the risk of

cross-contamination are followed

2. Monitor the observance ofGMP in the work area

2.1 Work practices conform to GMP requirements2.2 In-process and environmental monitoring occurs and is

recorded as required by GMP2.3 Personal hygiene and conduct of personnel in the work

area meets GMP requirements2.4 Personnel movement between work areas complies with

entry and exit procedures2.5 GMP-related data is recorded to meet workplace reporting

requirements

3. Respond to failures ornon-conformances

3.1 The scope of failures or non-conformances are defined3.2 Procedures to follow in the event of a failure are

documented3.3 Failures are investigated to determine root cause/s3.4 Risk assessment is conducted3.5 Findings are reported to meet GMP requirements3.6 Procedures are followed to implement and monitor

corrective and preventative action


FDFPHGMP4A Facilitate and monitor Good Manufacturing Practice


4. Complete work to meetGMP requirements

4.1 Processes are reviewed to ensure all procedures arecomplete

4.2 Line logs are reviewed to ensure documentation iscomplete

4.3 End of batch procedures are followed



Ability to:

• Locate regulations, codes, guides and internal company documentation relevant to GMPand products/processes used in the work area

• Use communication and document management systems to access and review relevantdocuments

• Ensure that operators have the required skills and knowledge

Knowledge of:

• Legislative framework and structure. This includes understanding of the role ofregulations, codes and guides

• Corporate and personal responsibility and liability for maintaining GMP in the workplace• Basic understanding of the Pharmaceutical Inspection Co-operation Scheme (PICS) and

related cross-recognition agreements• Basic understanding of the content covered by the Therapeutic Goods Act, relevant

codes and guides• Sources of technical advice on test methods and critical limits• Regulatory mechanisms including audit processes• Understanding of the principles of quality management, quality assurance and quality

control and the role of these activities in supporting GMP• Principles of risk management and related procedures• System for raising and managing corrective and preventative actions• Specific requirements to be met by manufacturing and/or packaging activities in the work

area to meet GMP requirements• Calibration programs and responsibilities• Procedures for reconciling materials and consumables and investigating discrepancies• Training system including assessment methods and documentation• Purpose, procedure and responsibility for specific systems, programs and procedures

to support GMP• Root cause analysis techniques• Workplace documentation and authorisation procedures




KEY COMPETENCIES







Solving problems -

Using technology -

RANGE STATEMENT


Regulations, codes andguides

• Relevant regulations, codes and guides include:• Therapeutic Goods Act• Therapeutic Goods Regulations• Australian Code of Good Manufacturing Practice for

Medicinal Products• TGA guides to interpretation of legal requirements• regulations, codes and guides related to other relevant

international legislation (appropriate to product andmarket)

• company policies and guidelines

Workplace documentation • Workplace documentation relevant to work area activitiesincludes

• company policies and guidelines• specifications• manufacturing formulae• processing and packaging instructions• batch production and packaging records• Standard Operating Procedures (SOPs)• OHS information including Material Safety Data Sheets

(MSDS)

Work practices • Work is carried out according to:• company policies and procedures• legislative and licensing requirements. This includes





Sources of technicaladvice

• Sources of technical advice include but are not limited to:• Therapeutic Goods Administration• British Pharmacopeia• European Pharmacopeia• US Pharmacopeia

Systems, programs andprocedures to supportGMP

• This includes but is not limited to:• line clearance• cleaning and sanitation• process control• control of cross-contamination• failure investigation• change control• validation• record keeping and documentation management• release for sale• internal audits

EVIDENCE GUIDE


Overview of assessment Assessment may occur in a real or simulated pharmaceuticalor complementary medicine manufacturing workplace wherethe assessment environment provides access to workplacedocumentation and document management systems related toGMP that are typical of commercial manufacturing businessesand meet the requirements of the Therapeutic Goods Act. It willalso provide a range of commercial production/packagingequipment and activities typically used in a commercialmanufacturing environment.


Workplace documentation relating to GMP.





Overlap with related units This unit is a core requirement for all pharmaceutical operatorsat AQF 4 and 5. It could be assessed concurrently with otherunits relating to problem solving and process improvement.This may include:










Evidence of participation in a project team to develop or reviewsystems and procedures to support GMP in a work area. Thisincludes providing evidence that the candidate:

• Provides documented evidence through use of workplacedocumentation and records to show that the workpreparation, processing and completion meet GMPrequirements.

• Leads response to a failure or non-conformance in thework area. This must include conducting risk assessment,analysing root cause analysis, identifying corrective andpreventive action and monitoring implementation. Thisaspect of assessment may be undertaken as part of ateam.




FDFPHRNC4A Respond to non-conformanceUnit Descriptor This unit applies to the pharmaceutical sector and covers the skills and

knowledge required to respond to non-conformance within level ofauthority and consistent with legal requirements.

Application of the Unit This unit can apply to people working in a supervisory or linemanagement production role. They would typically work as part ofa team responsible for investigating causes and controls toprevent recurrence of non-conformance. Typical applications ofthis unit would include responding to deviation and incidentreporting results and may include participation in responding tocustomer complaints, product recalls and audit findings.Responding to non-conformance is typically within theparameters of established policies, plans and procedures.



1. Identify non-conformance 1.1 Workplace systems, reports and operating parameters aremonitored to identify non-conformance

1.2 Nature of non-conformance is identified and described1.3 Corrective and preventative action and reporting

procedures appropriate to nature of non-conformance arefollowed

2. Identify causes ofnon-conformance

2.1 Workplace systems are used to investigate possiblecauses of non-conformance

2.2 Risk assessment is conducted

3. Review processes tominimise the risk ofrecurrence

3.1 Solutions are identified and assessed to eliminate orminimise the risk of recurrence

3.2 An implementation plan is developed3.3 Workplace documentation is developed or reviewed to

support implementation3.4 Consultative mechanisms are established and/or reviewed

to support continuous improvement and communicateinformation


FDFPHRNC4A Respond to non-conformance




Ability to:

• Identify systems under which non-conformance may be raised. This includes a basicunderstanding of the provisions of the Therapeutic Goods Act as it relates to systemsincluding customer complaints, product recalls and auditing

• Identify relevant company policies and procedures relating to responding tonon-conformance and confirm level of authority and responsibility for participating inthese procedures

• Identify the components of the management system. This includes information recordingsystems (such as those to support traceability); identification of personnel responsiblefor assessing information and determining appropriate action; procedures to be followedin the event of a non-conformance, change management requirements and definitions ofroles and levels of responsibility

• Participate in the investigation of causes and review of arrangements and procedures inresponse to a non-conformance. This could involve reviewing responses to previousincidents to assess effectiveness and/or developing recommendations on appropriateprocedures

• Identify and/or develop the appropriate communication systems and channels forconsulting with people affected by any proposed changes

Knowledge of:

• Legal requirements relating to management of non-conformance• Systems and responsibilities for identifying, investigating and responding to

non-conformance• Consultation and communication methods required to investigate possible causes and

communicate changed practices and procedures• Change management procedures and responsibilities including the role of corrective and

preventative actions• Procedures for reviewing, amending and validation• Information systems, technologies and software to access and analyse information• Problem solving methods

KEY COMPETENCIES







Solving problems -

Using technology -




RANGE STATEMENT


Non-conformance Non-conformance may be assessed against policies,procedures, specifications and audit requirements

Implementation plan An implementation plan includes but is not limited to:

• allocation of responsibilities and roles• establishing and negotiating timelines and resources• documentation review• appropriate authorisation• identification of training/skill development requirements

Legal requirements Legal requirements are those prescribed in the TherapeuticGoods Act and other relevant legislation, regulations andcodes (relating to product and markets)

Systems Systems and responsibilities for identifying, investigating andresponding to non-conformance can include but are not limitedto:

• corrective and preventative action• customer complaints• product recall• audits (internal and external)

EVIDENCE GUIDE


Overview of assessment Assessment may occur in a real or simulated pharmaceuticalor complementary medicine manufacturing workplace wherethe assessment environment provides access to workplacedocumentation including production records and datamanagement systems related to managing non-conformancethat are typical of commercial manufacturing businesses andmeet the requirements of the Therapeutic Goods Act. It willalso provide access to workplace policies and procedures tosupport the management of non-conformance to meet therequirements of the Therapeutic Goods Act.





Workplace documentation relating to responding tonon-conformance.



MCMC410A Lead change in a manufacturing environment


FDFPIOWP4A Optimise a work process





Evidence of participation in a team responsible for respondingto deviation and non- conformance. This includes providingevidence developed by the candidate to:

• Identify deviation.• Identify and determine the nature of non- conformance.• Implement required corrective action and reporting.• Investigate the causes of a non-conformance.• Identify changes to company systems and procedures

required to minimise the risk of recurrence.• Follow procedures to participate in proposing changes.• Develop and implement required preventative action.





Unit Descriptor This unit provides an overview of the documentation requirements asoutlined in Chapter 4 of the Australian Code of Good ManufacturingPractice for Medicinal Products and should be read in conjunction withthis document.

The unit covers the skills and knowledge required byproduction/packaging line managers or supervisors to develop, reviewand manage workplace documentation.

Application of the Unit This unit applies to people working in a supervisory or linemanagement production/packaging role. Their responsibilities fordocument design, review and maintenance would typicallyrequire them to work in close consultation with others and focuson documentation relevant to their work area.



1. Workplace documentationis developed and/orreviewed to meet GMPrequirements

1.1 Policies and master plans are identified to determine workarea requirements

1.2 Workplace documentation is identified and reviewed toconfirm GMP requirements are met

1.3 Procedures and records are developed and/or reviewedto confirm GMP requirements are met

1.4 Improvements to workplace documentation are identifiedand reported

1.5 Procedures to alter workplace documents are followed

2. Development andcommunication ofworkplace documentationis facilitated

2.1 Workplace documentation is developed in consultationwith relevant stakeholders to support GMP

2.2 Documentation is made available and clearly explained torelevant stakeholders

2.3 Training requirements are identified and addressed withinlevel of responsibility


FDFPHRWD4A Prepare and review workplace documentation to support GMP




Ability to:

• Use workplace documentation, recording and reporting formats and software• Prepare workplace documentation in plain English and suited to purpose and audience• Apply communication and consultation skills

Knowledge of:

• Documentation requirements (as outlined in Chapter 4 of the Australian Code of GoodManufacturing Practice for Medicinal Products)

• Document authorisation requirements and procedures and legal responsibilities ofsignatory

• Document types to support workplace systems and related development and controlsystems, roles and responsibilities. This includes an understanding of system securityand access levels

• Procedures and responsibilities for altering documents and managing version control• Systems, methods and procedures for recording and storing data and authorised levels

of access (to electronic systems)• Use of documentation including an understanding of the documents that can be used as

evidence in audit processes• Recording and reporting requirements• Training and assessment arrangements and responsibilities

KEY COMPETENCIES







Solving problems -

Using technology -




RANGE STATEMENT


Workplace documentation Workplace documentation may include but is not limited to:

• policies and master plans• quality manual• specifications• certificates• manufacturing formula• processing and packaging instructions• procedures• records• protocols (validation)• reports

Documentation typically includes:

• written descriptions• graphic display of information including diagrams and

photos• flow charts• Information is typically stored and accessed electronically




Procedures and records Information covered by procedures includes but is not limitedto:

• receipt of starting and packaging material• sampling• testing• release and rejection procedures• validation• equipment assembly and calibration• maintenance, cleaning and sanitation• personnel matters including training and personal hygiene• environmental monitoring• pest control• complaints• recalls• returns• equipment operation

Records should include but are not limited to:

• batch records• equipment recording (as appropriate)• validations• calibrations• maintenance• cleaning or repair work - including details of when/who• operating log sheets• complaints

Stakeholders Stakeholders refer to process and technical experts and mayinclude but are not limited to:

• operators• engineering department• quality assurance• area managers• related functions/personnel

Version control Version control includes the maintenance of workplacedocuments to meet company and regulatory requirements




EVIDENCE GUIDE


Overview of assessment Assessment may occur in a real or simulated pharmaceuticalor complementary medicine manufacturing workplace wherethe assessment environment provides access to workplacedocumentation and related document control and managementsystems that are typical of commercial manufacturingbusinesses and meet the requirements of the TherapeuticGoods Act. It will also provide a range of commercialmanufacturing packaging equipment and activities typicallyused in a commercial manufacturing environment.

Resources for assessment Australian Code of Good Manufacturing Practice for MedicinalProducts.

Workplace documentation and related document control andmanagement system.

Workplace personnel.


Overlap with related units This unit is a core requirement for all pharmaceutical operatorsat AQF 4 and 5. This unit could be assessed concurrently withother units relating to problem solving and processimprovement. This may include:










Provide evidence that the candidate:

• Reviews workplace documentation to confirm that itmeets GMP requirements. Documentation may relate to aspecific work area (rather than the whole plant). Thecandidate is required to document their findings.

• Develops, designs or amends documentation to supportGMP. For example, this could require the development ofoperating procedures. It may include reviewing andupdating existing documentation or developing newdocumentation within required formats. The candidatemust demonstrate application of document controlprocedures to submit or amend documents. They mustalso demonstrate that appropriate consultation wasundertaken in the development process and thedocument changes are effectively communicated. Thisincludes demonstrating an awareness of the link torelated documents. Where training needs arise from thechange, these must be identified together withrecommendations for how they can be addressed.

• Review completed GMP-related documents and recordsto ensure that GMP requirements are met.




FDFPHSPC2A Operate a separation process usingchromatography

Unit Descriptor This is a specialist unit. It covers the skills and knowledge required toset up, operate, adjust and shut down a chromatography processwhere this process is used in production contexts.




1. Prepare thechromatographyequipment for operation


1.2 Equipment is cleaned, assembled and adjusted to meetoperational requirements

1.3 Equipment components and related instrumentation areset to meet production requirements

1.4 Column status is checked and ready for operation1.5 Pre-start checks are carried out as required by work

practices1.6 Equipment status reports are completed as required by

workplace system

2. Prepare the samples andload product

2.1 Pre-sampling tests are conducted according to testmethod to confirm column operation

2.2 Tests results are interpreted2.3 Out-of-specification results are identified, investigated to

identify cause and reported according to workplaceprocedures

2.4 Product is loaded into columns

3. Operate and monitor thecolumn operation

3.1 The process is started and operated according to workpractices

3.2 Equipment is monitored to confirm that process cyclesoccur in the correct sequence

3.3 Variation in equipment operation and process outcomes isidentified and promptly reported according to workplacereporting procedures

3.4 Separation of solution meets specifications3.5 Workplace documentation is maintained according to

workplace reporting requirements

4. Shut down the columnprocess




FDFPHSPC2A Operate a separation process using chromatography




Ability to:

• Select, fit and use personal protective clothing and/or equipment. This includes gowningup, following required work area entry and exit procedures and moving around the workarea to minimise risk of contamination

• Prepare equipment for operation. This may involve inspecting equipment condition toidentify any signs of wear; disinfecting and sterilising equipment and surfaces;assembling columns; confirming that connections and valves are correctly positioned,column lines have been purged and all safety guards are in place and operational;selecting instrumentation settings; cancelling isolation or lock outs as required; andconducting pre-start checks to check equipment readiness

• Carry out sample testing to confirm integrity of columns. This is typically done byconducting a Height Equivalent to Theoretical Plate (HETP) test

• Demonstrate procedure for loading/packing product into columns• Start, operate, and monitor the process to achieve required outcomes. This may include

monitoring:• chromatography cycles• correct collection of fractions as required• appropriate product segregation• pump operation

• Take corrective action in response to out-of-specification results• Maintain security, integrity and traceability of samples, sub-samples and documentation• 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 ofresponsibility

• Demonstrate product/process changeovers. This includes demonstrating columnstorage procedures

• Follow end of batch procedures including line clearance and cleaning, yield calculation,materials reconciliation and product labelling


Knowledge of:

• Purpose and principles of chromatography. This includes an understanding of theprocess, purpose and methods used for analysis and preparation

• Basic operating principles of chromatography equipment. This may include anoperational understanding of the main equipment components, consequences ofincorrect equipment preparation (i.e. incorrectly positioned non-return valve, supplypump failure, air in the column)

• Quality characteristics and legal requirements to be achieved by the separation process• Operating requirements and parameters and corrective action required where operation


symptoms of faulty equipment and early warning signs of potential problems• Sample test methods and action required if results are out-of-specification (i.e. action

required if the HETP fails)• Procedures to collect fractions as appropriate to columns and process requirements• Procedures to identify traces as required and corrective action where traces are not

within specification




• Typical profile for a product cycle and the events to be monitored during the cycle• Procedures used to ensure product segregation• Analysis and interpretation of relevant test results and implications for action required• GMP/GLP requirements associated with chromatography process and related control

measures• Common causes of variation and corrective action required• OHS hazards and controls. This includes an awareness of the limitations of protective

clothing and equipment used• Procedures and requirements of different shut downs including an understanding of the

requirements for column storage, emergency and routine shut downs and procedures tofollow in the event of power outage

• Line clearance, cleaning and sanitation procedures• Isolation, lockout and tag out procedures and responsibilities• Procedures and responsibilities for reporting production and performance information

KEY COMPETENCIES







Solving problems -

Using technology -

RANGE STATEMENT




(MSDS)

Equipment Chromatography equipment includes columns, flow meters, UVmeters, filters and air sensors. Methods may include ionexchange, gel filtration and size exclusion filtration





• company policies, test methods and procedures• legislative and licensing requirements. This includes


EVIDENCE GUIDE


Overview of assessment Assessment may occur in a real or simulated workplacecontext. Where a simulated environment is used, it shouldprovide access to workplace documentation, chromatographyequipment, together with a typical range of samples to betested.

Resources for assessment Workplace documentation relating to separation process andprocedures.


Pre-requisite Unit FDFZPRCR2A Work in a clean room environment


Assessment of this unit would typically involve observation ofthe operator preparing, operating and shutting down theseparation process to meet production requirements.Observation should be sufficient to confirm consistentperformance.



• Performs sample testing to confirm integrity of columns.• Starts up, operates and monitors chromatography

process to ensure separation of solutions to meetspecifications.





FDFPHVP4A Participate in validation processesUnit Descriptor This unit provides an overview of validation processes used to support

GMP in the pharmaceutical sector. The unit is based on Annex 15 ofthe Australian Code of Good Manufacturing Practice for MedicinalProducts and should be read in conjunction with this document.

The unit covers the skills and knowledge required byproduction/packaging line managers or supervisors to participate invalidation processes. This person would not typically have responsibilityfor validation but would require an understanding of the purpose,procedures and responsibilities for different types of validation.

Application of the Unit This unit applies to people working in a supervisory or linemanagement role. Their involvement in validation would typicallybe as part of a multi-disciplinary team.



1. Participate in qualificationprocesses for new ormodified facilities,systems or equipment

1.1 Responsibilities and procedures for developing andimplementing design qualification, installationqualification, operational qualification andperformance qualification are identified

1.2 Qualification processes and documentation are developedor reviewed within level of responsibility

1.3 Workplace procedures are documented to supportoperational requirements

2. Participate in validationprocesses for new ormodified facilities,systems or equipment

2.1 Validation requirements in the work area are identified2.2 The validation protocol is followed to support validation

activities in the work area2.3 Data is collected, analysed and reported to meet GMP

requirements






Ability to:

• Apply principles of risk management to identify critical facilities, systems and equipment• Identify and interpret validation documentation relating to qualification and validation

requirements for a work area• Participate in qualification and validation procedures within level of responsibility• Identify and manage the impact of qualification and validation procedures on related

processes or work areas/personnel within level of responsibility• Liaise with other relevant departments/functions to co-ordinate and schedule validation

processes• Develop documentation to support qualification and validation according to required

formats and within level of responsibility• Ensure that operators in the work area have the required skills and knowledge• Prepare workplace documentation in plain English and suited to purpose and audience

Knowledge of:

• Principles and purpose of qualification and related procedures and responsibilities• Principles and purpose of validation and related procedures and responsibilities• Purpose and application of prospective, concurrent and retrospective validation• Data collection, analysis and reporting requirements• Scope, application and timing of validation including any relevant circumstances that

could trigger the need to validate or re-validate or justify not carrying out a validationprocess prior to production starting

• Relationship between validation and change control• Equipment design drawings and process flow charting• Relevant investigation methods including process capability and root cause analysis• Recording and reporting requirements• Training and assessment arrangements and responsibilities• Workplace documentation and authorisation procedures

KEY COMPETENCIES







Solving problems -

Using technology -




RANGE STATEMENT


Design qualification Demonstrates and documents compliance with GMP designrequirements

Design requirements of facilities and equipment must meetthose outlined in Australian Code of Good ManufacturingPractice for Medicinal Products, Chapter 3

Installation qualification Installation qualification includes but is not limited to:

• checking of equipment, piping, instrumentation andservices installation checked against current engineeringdrawings and specifications

• P&IDs (piping and instrumentation diagrams), operatingmanuals and other supplier information relating tooperation and maintenance

• calibration requirements• cleaning and sanitation inspection requirements• safety issues• environmental issues

Operational qualification Operational qualification includes but is not limited to:

• tests of processes, systems and equipment to confirmthat functioning meets agreed criteria within operatingconditions

• calibration plans• preventative maintenance plans• operating, cleaning and sanitation operating procedures

(SOPs)• training programs and schedules• recording requirements

Performance qualification Performance qualification may include but is not limited to:

• tests - using production materials, qualified substitutes orsimulated product - that have been developed fromknowledge of the process, facilities, systems orequipment

• tests to include a condition or set of conditionsencompassing upper and lower operating limits




Validation requirements Validation requirements include but are not limited to:

• process validation• packaging validation• cleaning validation• calibration validation• test method validation• validation of computerised systems• revalidation of in-use processes

Validation protocol A validation protocol includes but is not limited to:

• a short description of the process• summary of the critical step/s being investigated• list of equipment/facilities to be used (including

measuring/monitoring equipment) together with itscalibration status

• finished product specifications for release• list of analytical methods, as appropriate• proposed in-process controls with acceptance criteria• additional testing to be carried out, with acceptance

criteria and analytical validation, as appropriate• sampling plan• methods for recording and evaluating results• roles and responsibilities• proposed timetable

Validation documentation Documentation may include but is not limited to:

• validation master plan• protocols• reports• operating procedures and work instructions• OHS and environmental requirements• manufacturers' specifications




EVIDENCE GUIDE


Overview of assessment Assessment may occur in a real or simulated pharmaceuticalor complementary medicine manufacturing workplace wherethe assessment environment provides access to workplacedocumentation relating to qualification and validationprocesses that are typical of commercial manufacturingbusinesses and meet the requirements of the TherapeuticGoods Act. It will also provide a range of commercialproduction/packaging equipment and activities typically used ina commercial manufacturing environment.

Qualification processes may be simulated to allow a walkthrough of the process.


Workplace documentation including procedures relating toqualification and validation.





FDFPHCC4A Participate in change control procedures










Evidence of participation in a team responsible for validationprocesses. This includes providing evidence developed by thecandidate to:

• Review the qualification and validation protocols toassess implications for a work area and relateddepartments/functions.

• Participate in qualification procedures - DesignQualification (DQ); Installation Qualification (IQ),Operational Qualification (OQ), and/or PerformanceQualification (PQ). For example, this could includeconducting trials in the work area as part of performancequalification in a work area. The assessment activityrequires use and/or development of checklists and toolsin required formats to carry out qualification as part of aproject team. It also includes monitoring and reporting onoutcomes.




FDFPASFF2A Operate a pastry forming and filling processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a process to deposit fillings into apastry shell or onto a pastry sheet which is then topped or formed toproduct specifications.

Unit Sector Pastry


1. Prepare the pastryforming and fillingequipment and processfor operation







2. Operate and monitor thepastry forming and fillingprocess








3. Shut down the pastryforming and filling process





FDFPASFF2A Operate a pastry forming and filling process


RANGE STATEMENT





• Equipment may include filling, depositing, forming andweighing equipment, various sized and shaped trays andtins, and rework bins in line hoppers. Specific conveyorline attachments depend on product types and mayinclude spike rollers and cutters. Weighing and measuringequipment may include both manual and automatedsystems. Finishing attachments may be used such asshakers and topping equipment

• Fillings may be sweet or savoury and hot or cold• Operators carry out changeovers within workplace








EVIDENCE GUIDE


Ability to: • Access workplace information to identify pastry formingand filling processing requirements


• Confirm supply of necessary materials and services. Thisincludes the transfer of fillings and pastry to theproduction line to meet production requirements

• Confirm condition of materials. This may includeconfirming that pastry types and fillings match productspecifications; and that tin spray, water and egg yolkspray, are available as required. It may also includesdetermining if rework pastry is suitable for use

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured forpastry forming and filling processing requirements;sensors and controls are correctly positioned; anyscheduled maintenance has been carried out, and that allsafety guards are in place and operational, trays areavailable and positioned

• Start, operate, monitor and adjust pastry forming andfilling process equipment to achieve required outcomes.This may include monitoring control points andconducting inspections as required to confirm processremains within specification. Monitoring may include:• pastry thickness• alignment of deposited filling in relation to pastry sheet

or shell• amount and/or rate of filling deposited• product weight• enclosure of pastry product by forming, rolling or

covering with a pastry top• application of toppings/finishes as required• appearance (size and shape)

• Monitor supply and flow of materials to and from thepastry forming and filling process and equipmentoperation to confirm process remains within specification




required to take pastry forming and filling process andrelated equipment off-line in preparation for cleaningand/or maintenance within level of responsibility

• Demonstrate batch/product changeovers




Knowledge of: • Purpose and basic principles of the pastry forming andfilling process

• Basic operating principles of equipment. This may includean operational understanding of the main equipmentcomponents and attachments, status and purpose ofguards, equipment operating capacities and applications,and the purpose and location of sensors and relatedfeedback instrumentation. It may also include selectionand fitting of appropriate filler heads and/or finishingattachments, knowledge of services required and actionto take if services are not available

• The flow of the pastry forming and filling process and theeffect of outputs on customer satisfaction anddownstream processes such as freezing or baking

• Quality requirements of materials/ingredients and effect ofvariation on pastry forming and filling processperformance

• Quality standards required of the filled product• Pastry forming and filling process specifications,

procedures and operating parameters. This includesprocedures for preparing fillings, operating the depositingprocess, and operating closing (lidding) and finishing asrequired by product specifications



• Methods used to monitor the pastry forming and fillingproduction process. This may include inspecting,measuring and testing as required by the process. Itrequires awareness of inspection or test points (controlpoints) in the process and the related procedures andrecording requirements

• Contamination/food safety risks associated with thepastry forming and filling process and corrective actionrequired


• OHS hazards and controls. This includes awareness ofthe limitations of protective clothing and equipmentrelevant to the pastry forming and filling process



• Pastry forming and filling process changeover proceduresand responsibilities











Pre-requisite units









parameters• Specifications, control points and processing parameters• Production schedule and recipe/batch instructions• Pastry forming and filling process and related equipment

and services• Filling ingredients and pastry to be filled and/or formed• Sampling schedules and test procedures and equipment


required





FDFPASMD2A Operate a doughnut making processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down the doughnut manufacturingprocess.

Unit Sector Pastry


1. Prepare the doughnutmanufacturing equipmentand process for operation







2. Operate and monitor thedoughnut manufacturingprocess








3. Shut down the doughnutmanufacturing process





FDFPASMD2A Operate a doughnut making process


RANGE STATEMENT





• Doughnut types may include hole doughnuts and jaminjected doughnuts. Doughnut may be glazed or coveredwith topping

• Materials typically include flour, yeast, water, ice, oil,glazes, toppings and pre-mixes

• Equipment may include scales, mixers, hoppers, formingequipment, cutters or injectors, gas or electric fryingequipment, provers, enrobers and other glazing andequipment such cooling tunnels or spirals. Specificconveyor line attachments depend on product types

• Weighing and measuring may be automated or donemanually








EVIDENCE GUIDE


Ability to: • Access workplace information to identify doughnutmanufacturing requirements


• Confirm supply of necessary materials and services• Confirm condition of materials. This can include

confirming flour and water temperature, flour type, and oiltype

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters,cancelling isolation or lockouts as required; andconfirming that equipment is clean and correctlyconfigured for processing requirements; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational. This may includepre-start checks for:• doughnut mixing and forming equipment• deep frying equipment• cooling tunnels/spirals

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoring:• materials transfer prior to commencing mixing• mixing parameters such as water and flour

temperature, sequence of ingredient addition andmixing times

• forming parameters including air pressure to maintainweight of doughnut

• proving parameters which may includehumidity/temperature within prover and time

• frying parameters which may include oil temperature,appearance of cooked doughnuts, and time







• Operating finishing/filling equipment. This may include




preparing decorating ingredients such as mixing andheating; and crushing, cutting or sieving toppings.Monitoring may include temperature of toppings,spread/application of toppings and glazes, jam/fillingplacement and quantity and appearance of finishedproduct





Knowledge of: • Purpose and basic principles of the doughnutmanufacturing process. This includes an understanding ofthe stages in doughnut manufacture such as mixing,proving, frying and finishing and the requirements of eachprocessing stage such as the relationship betweentemperature, time and humidity in the proving process. Italso includes an understanding of the role of mainingredients such as yeast


• The flow of the doughnut manufacturing process and theeffect of outputs on customer satisfaction anddownstream processes such as packaging

• Quality requirements of materials and effect of variationon doughnut manufacturing process performance

• Quality characteristics to be achieved by the finisheddoughnut

• Process specifications, procedures and operatingparameters. This may include procedures for adjustingwater temperature to compensate for atmosphericconditions

• Operating requirements and parameters and correctiveaction required where results are out-of-specifiedoperating parameters


• Methods used to monitor the doughnut manufacturingprocess. This may include inspecting, measuring andtesting as required by the process. It requires awarenessof inspection or test points (control points) in the processand the related procedures and recording requirements

• Contamination/food safety risks associated with thedoughnut manufacturing process and related controlmeasures


• OHS hazards and controls. This includes awareness ofthe limitations of protective clothing and equipmentrelevant to the doughnut manufacturing process








• Environmental issues and controls relevant to thedoughnut manufacturing process. This includeswaste/rework collection and handling procedures relatedto the process


• Finishing requirements. This may include preparationmethods, monitoring of parameters such as icingtemperature, operating procedures for application offinishings and quality requirements such as evencoverage





Pre-requisite units












parameters• Production schedule and recipe/batch instructions• Specifications, control points and processing parameters• Doughnut mixing, forming, proving, injecting, and frying

equipment and related equipment as required such asglazing and topping application equipment

• Doughnut ingredients and related materials such as fryingoil and glazing/toppings and fillings as required



Assessment requirements For information on how to assess this competency standardand who can assess, refer to the Assessment Guidelines forthis Training Package




FDFPASMG2A Operate a griddle production processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a griddle production process.Unit Sector Pastry


1. Prepare the griddleproduct manufacturingequipment and processfor operation







2. Operate and monitor thegriddle productmanufacturing process

2.1 The griddle product manufacturing process is started andoperated according to workplace procedures



2.4 The process is monitored to confirm that the mix isprepared, formed and cooked to specification




3. Shut down the griddleproduct manufacturingprocess





FDFPASMG2A Operate a griddle production process


RANGE STATEMENT





• Griddle product types may include crumpets and pikelets• Materials typically used may include flour, water, eggs,

sugar, yeast, flavourings, colourings, spices, and otheradditives

• Equipment may include weighing, mixing, depositing andcooking equipment and cooling fans/tunnels andextraction fans. Specific conveyor line attachmentsdepend on product types. Weighing and measuringequipment may include both manual and automatedsystems








EVIDENCE GUIDE




• Confirm supply of necessary materials and services• Confirm condition and quantities of ingredients required.

This may involve weighing or confirming ingredientweights

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters,cancelling isolation or lockouts as required; andconfirming that equipment is clean and correctlyconfigured for processing requirements; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational, determine accuracyof scales

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoring:• materials transfer prior to commencing mixing• mixing parameters, water temperature, sequence of

ingredient addition, mixing times and mix consistency• depositing parameters to achieve product size and

weight. This may involve monitoring levels of mixture inhopper and alignment/position of deposited mixture

• griddle line equipment. This may involve monitoringtemperature of cooking surface; size, shape and colourof product; and moisture content of product

• cooling equipment, and time• Take corrective action in response to out-of-specification










Knowledge of: • Purpose and basic principles of griddle productmanufacturing


• The flow of this process and the effect of outputs oncustomer satisfaction and downstream processes


• Quality characteristics to be achieved by griddle products• Griddle product manufacturing process specifications,

procedures and operating parameters• Operating requirements and parameters and corrective






• OHS hazards and controls. This includes awareness ofthe limitations of protective clothing and equipmentrelevant to the griddle product manufacturing process

• Requirements of different shutdowns as appropriate tothe griddle product manufacturing process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage













Pre-requisite units









parameters• Production schedule and recipe/batch instructions• Specifications, control points and processing parameters• Griddle line and related equipment and services• Ingredients to produce griddle product• Sampling schedules and test procedures and equipment


required





FDFPASMP2A Operate a pastry production processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a pastry production process. Thisincludes mixing and sheeting or layering processes.

Unit Sector Pastry


1. Prepare the pastrymanufacturing equipmentand process for operation


1.2 Materials are weighed/loaded to meet productionrequirements


1.4 Services are confirmed as available and ready foroperation


1.6 The process is set to meet production requirements

2. Operate and monitor thepastry manufacturingprocess

2.1 The pastry manufacturing process is started and operatedaccording to workplace procedures



2.4 The process is monitored to confirm that dough mixing,rolling and laminating specifications are met




3. Shut down the pastrymanufacturing process





FDFPASMP2A Operate a pastry production process


RANGE STATEMENT





• Pastry types may include top and bottom pastry, andsweet or savoury pastry

• Pastry ingredients typically include flour, water, ice, fat(animal or vegetable), salt, baking powder, pre-mixes,melinta, metrex, sodium propate, rework pastry, sugarand yeast

• Ingredient transfer and loading may involve use of bulkmaterials handling equipment. It is typically partly or fullyautomated and may involve manual addition of someingredients

• Equipment may include weighing, mixing,laminating/rolling, cutting and stacking, and testingequipment. Conveyor line attachments depend onproduct types and may include spike rollers and cutters.Weighing and measuring equipment may include bothmanual and automated systems








EVIDENCE GUIDE


Ability to: • Access workplace information to identify pastrymanufacturing processing requirements


• Confirm supply of necessary materials and services. Thismay include flour, fat, rework; and ingredients areselected in accordance with recipe specifications

• Confirm condition and quality of ingredients• Conduct pre-start checks. This may involve inspecting

equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured forpastry manufacturing processing requirements; sensorsand controls are correctly positioned; any scheduledmaintenance has been carried out; that all safety guardsare in place and operational; and that rework bins arepositioned

• Start, operate, monitor and adjust pastry manufacturingprocess equipment to achieve required outcomes. Thiscan include setting up and starting up mixers, rollers andlaminating processes to meet production requirementsand may also include monitoring control points andconducting inspections as required to confirm processremains within specification

• Monitor supply and flow of materials to and from thedough preparation process and equipment operation toconfirm process remains within specification. This caninclude monitoring:• flour temperature and type• water temperature• fat type, distribution and percentage as required for

specific pastry types• rework pastry addition• dough characteristics• mixing time

• Roll and laminate dough to specification. This includesensuring in-line hoppers are filled with flour to preventpastry sticking to rollers and that roller settings are withinspecification. It also involves checking pastry thickness,fat percentage and the number of pastry layers.

• Monitor supply and flow of materials to and from thelaminating process and equipment operation to confirmprocess remains within specification

• Cut and stack or roll pastry according to productionrequirements


• Respond to and/or report equipment failure within level of





required to take pastry manufacturing process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility








Knowledge of: • Purpose and basic principles of the pastry manufacturingprocess


• The flow of the pastry manufacturing process and theeffect of outputs on customer satisfaction anddownstream processes such as filling, forming and baking

• Quality requirements of materials/ingredients and effect ofvariation on pastry manufacturing process performance

• Quality standards required of the finished pastry• Pastry manufacturing process specifications, procedures

and operating parameters. This includes procedures forpreparing dough, laminating, rolling, and cutting andstacking of pastry



• Methods used to monitor the pastry manufacturingproduction process. This may include inspecting,measuring and testing as required by the process. Itrequires awareness of inspection or test points (controlpoints) in the process and the related procedures andrecording requirements

• Contamination/food safety risks associated with thepastry manufacturing process and related controlmeasures

• Common causes of variation and corrective actionrequired. This includes an understanding of therelationships between time and temperature and humidityin the pastry manufacturing process

• OHS hazards and controls. This includes awareness ofthe limitations of protective clothing and equipmentrelevant to the pastry manufacturing process

• Requirements of different shutdowns as appropriate tothe pastry manufacturing process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage



• Environmental issues and controls relevant to theprocess. This includes waste/rework collection andhandling procedures related to the pastry manufacturing




process



• Pastry manufacturing process changeover proceduresand responsibilities




Pre-requisite units









parameters• Production schedule and recipe/batch instructions• Specifications, control points and processing parameters• Pastry manufacturing process and related equipment and

services• Pastry ingredients• Sampling schedules and test procedures and equipment


required





FDFPMMAC5A Manage supplier agreements and contractsUnit Descriptor This unit covers the skills and knowledge required to manage internal

and external agreements for the supply of goods and/or services. Thisunit can apply to the evaluation and management of existingcontractual arrangements and the development of new arrangements. Itrequires an understanding of supply chain relationships andarrangements.

Unit Sector People Management/Workplace Relationships


1. Establish contractualarrangements

1.1 Specifications for the delivery of goods and/or services aredocumented and agreed

1.2 Criteria for selection of suppliers are developed anddocumented

1.3 Potential suppliers are identified and assessed againstselection criteria

1.4 Supply contracts are documented and agreed by theparties

1.5 Contingency plans are developed in the event of supplierfailure to deliver

2. Administer and evaluatedelivery of goods and/orservices againstagreements

2.1 The quality of goods and services supplied is assessedagainst specifications

2.2 Non-compliance is identified, documented and correctiveaction is implemented within the terms of contractualarrangements

2.3 Relationships with suppliers are managed to supporteffective delivery

2.4 Vendor agreements are reviewed and renegotiated asrequired to ensure timely delivery and cost effectivesupply of quality goods and services

RANGE STATEMENT


Range description • Service agreements are consistent with company policyobjectives, legislative requirements, industry standards,codes and guidelines, industrial awards and agreements


FDFPMMAC5A Manage supplier agreements and contracts


EVIDENCE GUIDE


Ability to: • Identify the system in place to support management ofsupplier relationships, agreements and contracts. Thisincludes goods and services specifications, existingvendor agreements and contracts, traceability systemsand procedures, receivals procedures, invoicing systemand related documentation. This may involve identifyingexisting system features and/or identifying systemrequirements and developing appropriate systemcomponents

• For a range of goods and services, identify and/ordevelop criteria for selection of suppliers. The criteriashould reflect the company's approach to supply chainmanagement and take account of existing procurementpolicies including any preferred supplier arrangements aswell as historical experience with suppliers

• For a range of goods and services, identify current andpotential suppliers with the capacity to meet suppliercriteria. Establish a contingency supply plan in the eventof failure to deliver within the terms of the agreement

• For a range of goods and services, identify and/ordevelop a goods/service agreement to address companyrequirements. Identify and/or establish procedures tonegotiate the terms of the agreement with the supplierwithin level of responsibility

• Identify and/or establish procedures to receive andevaluate goods/services against agreed criteria. Thisincludes procedures for responding where goods/servicesare not within specification, within level of authority

• Identify and/or establish recording and communicationsystems to document contract compliance issues


• Monitor that contractors working on-site are inducted andaware of their roles and responsibilities




Knowledge of: • Approaches to supply chain management. This includesan understanding of customer-led models such asEfficient Consumer Response (ECR); the contrastbetween independent company operations versus chainpartnership arrangements; and the implications of asupply chain approach for the nature of the relationshipsbetween the company and its suppliers including level ofinformation sharing and co-operation

• The company's approach to supply chain management,and related systems and documentation in place tosupport internal management and supplier relationshipmanagement. This includes an understanding of levels ofauthority

• Appropriate technical knowledge to determine capacity ofa supplier to deliver and to assess quality ofgoods/service supplied. This may be addressed byidentifying relevant technical expertise such as aquality/laboratory function

• Legal rights and responsibilities of both the company andthe supplier

• The role of benchmarking in determining appropriatecriteria for supplier selection and contract management

• Appropriate measures of contract delivery and relativeimportance/weighting given by the company


• Induction and duty of care responsibilities for contractorsworking on-site


Pre-requisite units






• Workplace procurement policies and relateddocumentation and systems

• Relevant legislation, codes of practice and agreements• Access to suppliers of goods and services• Information management systems including planning,

recording and reporting systems• Technical support and advice as appropriate





FDFPMMPW4A Manage people in the work areaUnit Descriptor This unit covers the skills and knowledge required to manage people

performance issues. It is appropriate for those with managerialresponsibility for other people in a work area. It includes anunderstanding of different levels of response to performance issuesincluding formal disciplinary procedures.

Prerequisite Unit(s) FDFOPTSM3A Support and mentor individuals and groupsUnit Sector People Management/Workplace Relationships


1. Provide information onperformance expectations

1.1 Workplace policies and procedures are current, accessibleand in formats appropriate to the audience

1.2 Performance-related information is current, accessible andin formats appropriate to the audience

2. Provide coaching andsupport

2.1 Role models are provided to demonstrate appropriatework behaviours and procedures

2.2 Skill development needs are identified and addressed

3. Manage performanceissues

3.1 Signs of poor/unacceptable performance are identified3.2 Reasons for poor/unacceptable performance are

investigated3.3 Appropriate responsive action is identified and

implemented

RANGE STATEMENT


Range description • The management of people performance issues isconsistent with company policies and procedures,regulatory and licensing requirements, legislativerequirements, and industrial awards and agreements andtakes account of OHS and environmental impact ofscheduling arrangements

• People management may relate to a specific work area orapply across the workplace according to level ofresponsibility


FDFPMMPW4A Manage people in the work area


EVIDENCE GUIDE


Ability to: • Ensure that relevant and appropriate information isavailable to people in the work area to defineperformance expectations. This includes workplaceinformation on policies and procedures and on productiontargets/work outcomes required of the work role

• Ensure that appropriate behaviour/procedures areconsistently observed by all workplace personnel in thework area

• Establish skill shortages and arrange for these to beaddressed. This may involve direct training/explanation orreferral to appropriate personnel

• Provide regular feedback to foster confidence andappropriate workplace behaviours. This may includeproviding aggregate information on work performancesuch as KPIs as well as feedback on individualperformance and behaviour

• Identify indicators of poor or unacceptable workperformance and investigate cause/s

• Determine appropriate response within level ofresponsibility. This includes recording details ofperformance issues and response to meet workplacerecording requirements

• Develop a plan to structure and undertake a formalcounselling interview

• Demonstrate appropriate interview techniques to counselin response to a performance management issue




Knowledge of: • Workplace feedback and performance managementsystems and responsibilities in the workplace. Thisincludes personal level of authority for performancecounselling and disciplinary procedures

• Company policies, procedures and relatedcommunication systems

• The effect of personal style and behaviour on others inthe work area. This includes an understanding of theimportance of establishing effective relationships withpeople in the work area

• The importance of providing clear information onperformance expectations and related communicationsystems/processes

• Signs of poor performance. This includes patterns orbehaviour that may lead to poor performance

• Options and strategies to address performance issues.This includes an understanding of the difference betweencompetency performance and related responses

• Systematic approaches for structuring a discussion onpoor performance. At a minimum this includes a clearstatement of the problem, an explanation of why it is aproblem, the action or change required to address theproblem and any follow up action

• Workplace and legal requirements to document instancesof poor performance or unacceptable behaviour. Thisincludes an understanding of the legal processes thatcould eventuate and how reported information may beused

• Relevant provisions of relevant industrial awards andenterprise agreements on employee rights andresponsibilities related to work performance. Thisincludes an understanding of the relationship between theaward and site agreements. Provisions to be coveredinclude but are not limited to:• work allocation - minimum callouts/hours• notice periods required to change shifts

arrangements/allocations• classification structure relevant to work role/hours of

work• leave entitlements• conflict/dispute resolution procedures


• Recording systems and requirements





Pre-requisite units

The pre-requisite unit for this competency standard is:

• FDFOPTSM3A Support and mentor individuals andgroups





• Workplace policies and procedures• Relevant industrial awards and agreements• Workplace information recording systems, requirements

and procedures





FDFPMOHS4A Manage the implementation of occupationalhealth and safety policies and procedures inthe workplace

Unit Descriptor This unit covers the skills and knowledge required to manage theimplementation of occupational health and safety (OHS) policies andprocedures in one or more work areas. This unit applies to those withformal responsibility for others.

This unit is based on and achieves the outcomes of the NationalOccupational Health and Safety Commission (NOHSC) GenericOccupational Health and Safety Competency Standard B and parts ofStandard C in the National Guidelines for Integrating OccupationalHealth and Safety Competencies into National Industry CompetencyStandards [NOHSC: 7025 (1998) 2nd edition].

Unit Sector People Management/Workplace Relationships


1. Ensure others in the workarea are able toimplement safe workpractices

1.1 Hazard control equipment and personal protective clothingand equipment appropriate to work requirements areavailable and functional

1.2 Systems are implemented to confirm that others in thework area are aware of OHS policies, procedures andprograms

1.3 Information about identified hazards and the outcomes ofrisk assessment and risk control procedures is accessibleand communicated to others in the work area

1.4 Health and safety hazards and control measures relatingto work responsibilities can be identified by those in thework area

1.5 Mentoring and coaching is available to supportindividuals/groups to implement work procedures tosupport safety

1.6 Training needs are identified and addressed within level ofresponsibility

2. Monitor observance ofsafe work practices in thework area

2.1 Work procedures in the work area are clearly defined,documented and followed

2.2 Personal behaviour is consistent with workplace policiesand procedures

2.3 Non-compliance with documented work procedures isidentified and addressed in accordance with workplaceprocedures

2.4 Safety hazards in the work area are identified andreported according to workplace procedures

2.5 OHS records are reviewed to confirm that they arecompleted in an accurate, thorough and timely manner

2.6 Housekeeping standards in the work area are maintained


FDFPMOHS4A Manage the implementation of occupational health and safety policies and procedures in the workplace


3. Implement emergencyprocedures to respond toa hazardous event

3.1 Systems are implemented to confirm that others in thework area are aware of their role and the requiredresponse in case of emergency

3.2 Workplace procedures for dealing with hazardous eventsare promptly implemented as required

3.3 Hazardous events are investigated to identify cause3.4 Control measures to prevent recurrence and minimise

risks of hazardous events are implemented

4. Maintain and improvehealth and safety in thework area

4.1 Potential hazards are identified, assessed, removed orand/reported within level of responsibility and according toworkplace procedures

4.2 Risk assessments are conducted and appropriate controlmeasures are identified and implemented in the work area

4.3 Recommendations arising from risk assessments areimplemented within level of responsibility

4.4 Inadequacies in control measures are identified andreported according to company reporting requirements

4.5 Procedures are developed or revised to support effectivecontrol of health and safety hazards

4.6 Safety information is reviewed to identify opportunities forimproving OHS

5. Implement participativearrangements

5.1 The work group is consulted and advised of OHS mattersrelevant to work role

5.2 Outcomes of consultation on OHS issues are reportedback to the work group promptly

5.3 Matters raised relating to OHS are promptly resolved orreferred to appropriate personnel




RANGE STATEMENT


Range description • At this level the supervisor/manager is responsible formonitoring and managing implementation of OHSpolicies, procedures and programs across one or morework areas. This typically involves overseeingimplementation of OHS by a larger group and/or acrossmore diverse operations than would apply to a person atAQF 3

• Work is carried out in accordance with companyprocedures, regulatory and licensing requirements,legislative requirements, and industrial awards andagreements. Legislative requirements includeState/Territory/Commonwealth occupational health andsafety Acts and regulations, including regulations relatingto hazards present in the workplace. They also includegeneral duty of care under occupational health and safetylegislation and common law

• Company procedures may include job-related SOPs andOHS-specific procedures. Examples of OHS proceduresinclude consultation and participation requirementsincluding OHS issue resolution procedures, emergencyresponse, response to specific hazards, hazard andincident reporting, and investigation and risk assessment

• Workplace information will include OHS system andrelated documentation including policies and procedures,Standard Operating Procedures (SOPs), information onhazards and the work process, hazard alerts, safety signsand symbols, labels, Material Safety Data Sheets(MSDSs) and manufacturers' advice. Technical advicemay include codes of practice, Australian andinternational standards and other technical informationrelated to given hazards and risks and industry standards

• Work responsibilities include formal responsibility forproviding a support role to others in the work area and forcounselling others on unacceptable work performance

• Work procedures requiring documentation may includebut not be limited to work instructions; maintenancerequirements; inspections and housekeeping; specifichazards; reporting and investigation; identifying,assessing and controlling risks; use of personal protectiveequipment; provision of OHS information; andconsultation and participation

• Safe work procedures relate to the work area/s and mayinclude special requirements covered by the issuing ofpermits

• Employee and employer rights and responsibilities arethose established by legislation and reflected in companypolicies and procedures

• Hazards, near misses, injuries and illnesses relate to own




job and work area• OHS incidents include near misses, injuries, illnesses and

property damage• Hazards found in the work area can include but are not

limited to:• noise• confined spaces• working with steam and hot services/product• airborne particulates• handling hazardous substances• working with and near moving equipment/load shifting

equipment• stress• broken or damaged equipment or materials• slip, trip and fall hazards• manual handling• working with 240V power supply• poor ventilation• working in exposed weather conditions• working with combustible materials

• Where safety hazards include work conditions covered byNational Occupational Health and Safety Commissionand/or state health and safety authorities, the assessmentcriteria and methods prescribed by these authorities mustalso be met

• Consultation would typically address hazard reports;suggestions and concerns put forward by employees tomanagement; workgroup meetings; discussions andformal meetings with work group representatives; andconsidering and responding to feedback on issuesincluding but not limited to identification of hazards,assessment of risk level, hazard control options, injuryand accident investigation, development and/or review ofsafe work procedures and proposed changes to the workenvironment that may impact on risk. At this level, itincludes ensuring that effective consultation occurs

• The manager at this level is expected to be able to initiateinvestigations and risk assessments and assess theeffectiveness of control measures

• The manager may not have direct responsibility foroverseeing the training/development of team members.At a minimum they must identify development needs ofothers in the work area and refer this information to therelevant personnel. Training may include inductiontraining, specific hazard training, use of specificequipment, emergency response training and training aspart of developing broader job-related competencies

• Responsibilities at this level may include facilitatingconsultation processes within level of responsibility

• Record keeping complies with legal and OHS programrequirements. Records may include but are not limited tosafety audit and inspection reports, workplaceenvironmental monitoring records, maintenance and




testing records, hazardous substances registers, MaterialSafety Data Sheets, records of instruction and training,first aid records, workers compensation and return towork records




EVIDENCE GUIDE


Ability to: • Communicate information about OHS and relatedprocedures to others in the work area. This involvesselection of appropriate methods for communicatinginformation across a work area and facilitation ofstructured meetings and information forums

• Provide access to and maintain current OHS informationin the work area. Implement systems to confirm that thework group is aware of OHS policies and procedures

• Model safe work policies and procedures in own work• Ensure that safe work procedures are implemented by

others in the work area• Implement systems for identification of OHS hazards and

controls relevant to work processes and practices in thework area such as audits, workplace inspections, reviewof OHS records

• Support others to follow OHS procedures. This involvesensuring that all personnel in the work area receive theinformation and training required, that they have met thenecessary competency/regulatory and licensingrequirements to carry out their work responsibilities, thatthe appropriate risk control strategies and equipment arein place and they are equipped with the relevant personalprotective clothing and equipment. This may apply to bothcompany employees and subcontractors

• Counsel others on non-compliance in accordance withworkplace procedures

• Identify, report and/or address OHS training anddevelopment needs of others in the work area

• Lead investigations of non-compliance, risk assessmentsand incident investigations

• Lead consultation processes to improve OHS in theworkplace. Processes must provide opportunities for allemployees to participate

• Respond to OHS hazard identification and incidents in anappropriate and timely way

• Review practice and procedures to implementrecommendations arising from risk assessments and/orimprovement proposals within level of responsibility

• Review OHS records generated in the work area foraccuracy, completeness and timeliness

• Use OHS data to evaluate effectiveness of the OHSsystem and identify areas for improvement

• Plan implementation of improvements according toworkplace procedures

• Predict impact of planned changes on related work areaand consult as appropriate

• Design and plan changes to equipment and process totake account of OHS

• Participate in the development and implementation of




return to work arrangements within level of responsibility• Initiate processes to ensure that housekeeping standards

are maintained and that equipment is safe to operate




Knowledge of: • Roles and responsibilities associated with duty of care.This includes company and personal duty of care

• Legislation relating to OHS rights and responsibilities.This requires an understanding of the main provisions ofnational and state health and safety legislation,regulations and codes of practice. This includes OHSrights and responsibilities and codes of practice related toconsultation, safe workplace, workers compensation andreturn to work

• The system for managing OHS in the workplace. Thisincludes an understanding of specific programs tomanage OHS; the role of operating and safetyprocedures, incident reporting and investigationprocesses; training arrangements; structure and role ofconsultative processes; sources of information onworkplace health and safety; and OHS personnelincluding managers, representatives, emergencywardens, first aid officers and internal and externalauditors where appropriate

• Elements of an effective OHS management systemincluding the role of maintenance, purchasing,contractors, training, consultation, and planning

• Principles of risk management including hazardidentification, risk assessment and risk control accordingto hierarchy of control and the principles for choosingappropriate controls as applied within the industry and/orindustry sector

• Awareness of industry standards, practices and externalsources of technical information

• Hazards and control measures typically used in theindustry. This requires an understanding of safe workrequirements relevant to the work area, including lockout/tag out and isolation procedures

• The personal protective clothing and/or equipmentrequirements of work roles in the work area andprocedures for selecting, ordering clothing and/orequipment as required

• Purpose, application and limitations of protective clothingand equipment

• Common types of injuries relevant to work tasks, likelycauses and control options

• Work functions carried out in the work area that arecovered by special training requirements such as for entryto confined spaces, hot work, working at heights andmanual handling. Where appropriate, this includes anunderstanding of procedures and responsibilities forissuing work permits

• Consultation mechanisms and responsibilities• Appropriate communication skills and techniques to

convey health and safety information to others in theworkplace. This includes the ability to present informationin suitable formats for given audiences, facilitatestructured meetings and convene information forums as




appropriate within workplace consultation arrangements• Emergency response system, procedures and personnel• Return to work responsibilities and procedures• Auditing arrangements, roles and responsibilities as they

relate to the work area. This includes an understanding ofinternal and external audit processes

• Documentation system and procedures. This includesrecord keeping to meet both company and legalrequirements, procedures for developing and/or reviewingworkplace procedures and document control systemsused in the workplace

• Current practices used to evaluate OHS performance.This includes an awareness of OHS record keepingresponsibilities and methods of analysis including positiveand negative measures


Pre-requisite units



This unit should be assessed together with other units ofcompetence relevant to the function or work role. In addition,the following optional or ancillary units may be relevant:

• PMAPER300A Issue work permits• PMBOHS204B Apply emergency/incident procedures• FDFOPTPIP3A Participate in improvement processes• FDFOPTTG3A Lead work teams and groups• BSBCMN405A Analyse and present research information• FDFIMMIA4A Manage internal audits






• OHS legislation, regulations and codes of practice• Enterprise OHS policies and procedures• Work area or system in which OHS policies and

procedures are to be monitored• Standard operating procedures and related advice on

specific safe work practices• Advice on hazards and control procedures relevant work

area• Work tasks and related equipment to which OHS

procedures are to be applied• Personal protective clothing and equipment as required• Emergency and/or evacuation procedures for the

potential range of hazards• Competency records and workplace training

arrangements• Consultative forums relating to OHS• Storage areas for hazardous goods as required• OHS reporting systems and requirements• OHS data and performance reports• Manual handling equipment as required

Assessment requirements For information on how to assess this competency standardand who can assess, refer to the Assessment Guidelines forthis Training Package. For some types of audits, auditors arerequired to comply with assessment arrangements specified byrelevant regulatory bodies. Where this is the case, theseseparate assessment requirements must also be met.




FDFPHAFS2A Operate an aseptic fill and seal processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down an aseptic fill and seal process.This is a primary packaging process to fill product into packaging.

This unit is based on and equivalent to FDFZPKFS2A Operate a fill andseal process.

Prerequisite Unit(s) FDFZPRCR2A Work in a clean room environmentUnit Sector Pharmaceutical


1. Prepare the filling andsealing equipment andprocess for operation

1.1 Materials and packaging components/consumables areconfirmed and available to meet operating requirements



1.4 Operating parameters are entered as required to meetsafety and production requirements



2. Operate and monitor thefilling and sealing process




2.4 Packaging quality and seal integrity are monitored toconfirm that specifications are met

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

2.6 The workplace meets housekeeping standards2.7 Spillages are reported and removed according to standard

operating procedures2.8 Workplace records are maintained according to workplace


3. Shut down the filling andsealing process

3.1 End of batch procedures are completed in accordancewith batch instructions and standard operating procedures




FDFPHAFS2A Operate an aseptic fill and seal process


RANGE STATEMENT



• Legislative requirements are typically reflected inprocedures and specifications. Legislation relevant to thisindustry includes relevant Good Manufacturing Practice(GMP) codes, the Therapeutic Goods Act and/or otherrelevant legislation, and legislation coveringenvironmental management, occupational health andsafety, anti-discrimination and equal opportunity


• Filling and sealing equipment may include pumps, asepticfillers, hermetic sealers, and aseptic packaging

• Sterilisation methods used may include use of heat (dryand steam), chemicals (gases and liquids), gammairradiation, and filtration

• Work is carried out in a graded clean room environment.Refer to FDFZPRCR2A Work in a clean roomenvironment








EVIDENCE GUIDE



• Select, fit and use personal protective clothing and/orequipment. This includes gowning up, following requiredwork area entry and exit procedures and moving aroundthe work area to minimise risk of contamination

• Confirm supply of necessary packagingcomponents/consumables and product

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;disinfecting and sterilising equipment and surfaces;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured forpackaging requirements; packagingcomponents/consumables are loaded; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Start, operate, monitor and adjust the filling and sealingprocess equipment to achieve required outcomes. Thismay include monitoring control points and conductinginspections as required to confirm process remains withinspecification. This may include monitoring:• flow rates• weights and volumes• fill levels• temperature - includes materials and sealing

temperatures• supply of packaging components/consumables• packaging quality and seal integrity. This may include

testing packaging integrity• Take corrective action in response to out-of-specification

results• Monitor supply and flow of materials to and from the

process• Respond to and/or report equipment failure within level of


required to take filling and sealing process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility

• Demonstrate product/process changeovers• Follow end of batch procedures including line clearance

and cleaning, yield calculation, materials reconciliationand product labelling





Knowledge of: • Purpose and basic principles of filling and sealing. Thisincludes an understanding of the properties of packagingmaterials used, the principles of heat sterilisation and itseffect on micro-biological characteristics of the productand packaging materials, and the filling process. Methodsmay require exclusion of air using inert gas such asnitrogen and filling under vacuum

• Aseptic container preparation, handling and loading• Basic operating principles of aseptic filling and sealing

equipment. This may include an operationalunderstanding of main equipment components, statusand purpose of guards, equipment operating capacitiesand applications, and the purpose and location of sensorsand related feedback instrumentation and servicesrequired for operation of filling equipment used in theworkplace

• Quality characteristics and legal requirements to beachieved by the filling and sealing process. This mayinclude an understanding of quality requirementspackaging components/consumables, sterilisationrequirements and procedures, filling including fill levelsand weights, and requirements of seal formation andintegrity. It may require an understanding of integritytesting procedures

• The flow of processes supplying the filling and sealingprocess and the effect of outputs on downstreamprocesses



• Methods used to monitor the process. This may includeinspecting, measuring and testing as required by theprocess. It requires awareness of inspection or test points(control points) in the process and the related proceduresand recording requirements

• GMP requirements associated with the liquidmanufacturing process and related control measures

• Common causes of variation and corrective actionrequired. This includes an understanding of the effect ofvariation in both product and packagingcomponents/consumables on filling and sealingperformance. For example, it may include anunderstanding of the effect of temperature variation onthe filling process

• Product/packaging changeover procedures• OHS hazards and controls. This includes awareness of

the limitations of protective clothing and equipmentrelevant to the work process

• End-of-batch procedures including procedures forcalculating yield, materials reconciliation and action




required if yield/reconciliation is not within prescribedlimits, and product labelling responsibilities andprocedures


• Line clearance, cleaning and sanitation procedures• Isolation, lock out and tag out procedures and


and performance information• Environmental issues and controls relevant to the filling

and sealing process. This includes waste/reworkcollection and handling procedures related to the process



• Sampling and testing procedures• Routine maintenance procedures


Pre-requisite units

The pre-requisite for this competency standard is:

• FDFZPRCR2A Work in a clean room environment










GMP, quality and environmental requirements, stock flowsystems, production/packaging schedules


• Specifications, control points and operating parameters• Aseptic filling and sealing process and related equipment

and services• Materials and packaging components and consumables• Product• Sampling schedules and test procedures and equipment



required





FDFPHCLS2A Co-ordinate a label storeUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

manage a label store in a pharmaceutical workplace to meet workplaceand legislative requirements. This unit applies to management of asecure label store.

Unit Sector Pharmaceutical


1. Receive labels 1.1 Label details are identified and verified1.2 The quantity of labels received is counted and reconciled

against receivals documentation1.3 Discrepancies are identified, investigated and reported

2. Issue and reconcile labels 2.1 Labels are located/created to meet batch requirements2.2 Labels are issued in correct quantities to meet batch

requirements2.3 Labels returned to store are received, reconciled and

recorded according to verification and reconciliationprocedures

2.4 Records are maintained to meet workplace and legislativerequirements

RANGE STATEMENT




• Workplace information may include labels and relateddocumentation, Standard Operating Procedures (SOPs),production schedules and instructions, standard formsand reports


FDFPHCLS2A Co-ordinate a label store


EVIDENCE GUIDE


Ability to: • Follow receivals procedures to receive, count and storelabels

• Access production schedule to identify label requirements• Carry out procedures to test accuracy of label counting

machines and record results• Verify that label information meets batch type. This

typically requires setting up and using label countingequipment

• Demonstrate the procedure for removing and accountingfor damaged or other non-conforming labels

• Select and issue labels to meet batch requirements anddocumentation

• Demonstrate procedures to receive labels issued andreturned from production

• Conduct reconciliations of labels received and issued andconduct back up verification as required

• Maintain security of label store• Maintain work area to meet housekeeping standards


• Operate label coding and printing equipment

Knowledge of: • System of label control. This includes a detailedunderstanding of the purpose and procedures forreceiving, issuing, reconciling and verifying labelmanagement

• Legislative responsibilities relating to label management• Purpose and requirements of security procedures and

responsibilities• Types of labels received and issued and significance of

codes• Consequences of issuing incorrect labels• Procedures for setting up, testing and operating label

store equipment including label counting equipment• Corrective action required if a discrepancy is identified• OHS hazards associated with the work role• Procedures and responsibility for recording and reporting

information


• Operating procedures for label coding and printingequipment





Pre-requisite units



This unit should be assessed together with other units ofcompetence relevant to the work role.



• Label management system and procedures• Documentation and recording requirements and

procedures• Labels• Label counting equipment• Label printing equipment and consumables as required





FDFPHCP2B Operate a compressing processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down the compressing process.Unit Sector Pharmaceutical


1. Prepare the compressingprocess for operation







2. Operate and monitor thecompressing process

2.1 The compressing process is started and operatedaccording to workplace procedures



2.4 The process is monitored to confirm that tablet productmeets specifications





3. Shut down thecompressing process

3.1 End-of-batch procedures are completed in accordancewith batch instructions and standard operating procedures




FDFPHCP2B Operate a compressing process


RANGE STATEMENT





• Compressing equipment and accessories may includesingle punch compressors, rotary compressors, punches,and dies

• Stock for the process is supplied from the granulationprocess and the dispensing process

• Raw materials/ingredients which are added to thegranulated product may include diluents,adhesives/binders, disintegrants, glidants, lubricants,fillers, colourants, and flavouring agents

• In-process tests may include appearance, hardness,friability, disintegration, weight, and dimensions

• Work may involve exposure to dangerous and hazardoussubstances




• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, steam, water, vacuum, gases and compressedand instrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify compressingprocess requirements


• Confirm supply of necessary materials and services to thecompressing process

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingline clearance; installing punches and dies; confirmingthat related equipment is clean and correctly configuredfor processing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational

• Verify granules/powder blends with batch instructions• Start, operate, monitor and adjust compressing process

equipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• flow rates/quantity• tablet quality including weight, shape, hardness and

appearance• product labelling


• Monitor supply and flow of materials to and from thecompressing process



required to take compressing process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility

• Follow end of batch procedures including line clearanceand cleaning, yield calculation, materials reconciliationand product labelling



• Use process control systems• Collect samples and conduct tests• Conduct routine maintenance




Knowledge of: • Purpose and basic principles of the compressing process• Basic operating principles of equipment. This may include


• Purpose and characteristics of ingredients/raw materialsused and their role in the tablet

• Types of raw materials used in the encapsulation processand related handling/segregation requirements. This mayinclude handling hazardous goods

• Stages and changes which occur during compression• Quality characteristics and legal requirements to be

achieved by the compressed tablet• The flow of the compressing process and the effect of

outputs on downstream pharmaceutical processes• Operating requirements and parameters and corrective



• Methods used to monitor the compressing process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the processand the related procedures and recording requirements

• GMP requirements associated with the compressingprocess and related control measures




• End-of-batch procedures including procedures forcalculating yield, materials reconciliation and actionrequired if yield/reconciliation are not within prescribedlimits, and product labelling responsibilities andprocedures

• Requirements of different shutdowns as appropriate tothe compressing process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage



and performance information




• Environmental issues and controls relevant to thecompressing process. This includes waste collection andhandling procedures related to the process






Pre-requisite units








GMP, quality and environmental requirements• Information on equipment capacity and operating

parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Compressing process and related equipment and

services• Materials required for the compressing process• Sampling schedules and test procedures and equipment


procedures, including labels• Cleaning procedures, materials and equipment as

required





FDFPHDRM2A Dispense pharmaceutical raw materialsUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

weigh, measure and label non-bulk ingredients to meet batchrequirements.



1. Prepare to dispense rawmaterials

1.1 Materials are inspected to confirm type, quality clearance,quantities and identify any obvious contamination ornon-compliance

1.2 Measuring and weighing equipment is selectedappropriate to dispensing requirements and checked toconfirm readiness for use

1.3 Containers/bags and labels are available as required1.4 Pre-start checks are carried out as required by workplace

requirements

2. Measure and/or weigh rawmaterials

2.1 Non-bulk ingredients and additives are weighed/measuredto meet production requirements

2.2 Dispensed ingredients are labelled according to workplaceprocedure

2.3 Accuracy of measuring/dispensing equipment is monitoredto identify variation in operating conditions


2.5 Workplace housekeeping standards are maintained

3. Shut down the dispensingprocess

3.1 Dispensing equipment is cleaned according to workplaceprocedure

3.2 Unacceptable equipment/utensil condition is identified andreported

3.3 Dispensed materials are recorded and reconciled3.4 Maintenance requirements are identified and reported


FDFPHDRM2A Dispense pharmaceutical raw materials


RANGE STATEMENT




• Workplace information may include Standard OperatingProcedures (SOPs), specifications, production/dispensingschedules and instructions, batch/recipe instructions,manufacturers' advice, standard forms and reports

• Dispensing equipment may include scales, pipettes,calibrated measuring containers, fume cabinets,labels/printers and related dispensary instrumentation

• Raw materials may include drugs of addiction classifiedas S8






EVIDENCE GUIDE


Ability to: • Access workplace information to identify dispensingrequirements

• Select, fit and use personal protective clothing and/orequipment. This may include use of breathing apparatusand fume cabinets as required

• Confirm supply of necessary raw materials. This mayinclude checking raw material labels and codes, quantityand quality clearance

• Conduct pre-start checks on equipment. This may involveinspecting the condition and cleanliness of equipment andutensils, taring scales and carrying out any relatedprocedures to confirm that equipment is accuratelycalibrated and fit for use

• Measure materials and additives within specifiedaccuracy range to meet batch requirements

• Calculate assay/potency adjustment• Verify accuracy of raw materials dispensed with raw

materials records• Take corrective action in response to out-of-specification

results• Pace dispensing to meet production requirements• Pack and label dispensed materials as required• Follow labelling procedures• Reconcile and record materials dispensed against

materials released and return unused materials to storageas required

• Stack dispensed materials for transfer to designatedlocation ensuring required material segregation

• Handle containers according to workplace procedures tomaintain integrity of materials

• Clean dispensing equipment and utensils according toworkplace procedures


• Complete dispensing records as required by workplacerecording system



• Collect samples and conduct test




Knowledge of: • Purpose and basic principles of the dispensing process.This includes an understanding of the characteristics ofraw materials and related handling requirements

• Dangerous goods handling requirements and procedures• Relevant legislative responsibilities and workplace

systems for recording information on dispensedpharmaceutical materials and related workplace codingand labelling systems and purpose

• The relationship between the dispensing process andrelated operations. This includes an understanding ofaccuracy/tolerance and consequence of error

• Purpose, measuring/accuracy capacity of instrumentationand related equipment calibration responsibilities andprocedures

• Control points in the dispensing process• Procedures for calculating assay and adjusting potency• Raw materials reconciliation purpose and procedures.

This may include reconciliation of S8 materials• GMP requirements associated with the dispensing

process and related control measures• Procedures for requisitioning, receiving and returning

ingredients from stores• Typical equipment faults and related causes. This


• OHS hazards and controls. This includes an awarenessof the limitations of protective clothing and equipmentrelevant to the work process

• Cleaning, care and storage of equipment andinstrumentation used


• Environmental issues and controls relevant to thedispensing process. This includes waste/rework collectionand handling procedures related to the process




Pre-requisite units




• FDFOPTISP2A Implement sampling procedures• PMLTEST300A Perform basic tests• FDFZCSCS2A Clean and sanitize equipment







good manufacturing practice, standard operatingprocedures and environmental requirements


• Dispensing schedule, batch instructions• Specifications, control points and processing parameters• Dispensing process and related equipment and services• Materials required for the dispensing process• Containers/bags, labelling and storage facilities• Sampling schedules and test procedures and equipment



required





FDFPHEP2B Operate an encapsulation processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down the encapsulation process.Unit Sector Pharmaceutical


1. Prepare the encapsulationprocess for operation







2. Operate and monitor theencapsulation process

2.1 The encapsulation process is started and operatedaccording to workplace procedures



2.4 The process is monitored to confirm that capsules meetspecifications





3. Shut down theencapsulation process





FDFPHEP2B Operate an encapsulation process


RANGE STATEMENT





• Encapsulation equipment and accessories may includesemi-automatic filling machines, intermittent fillingmachines, continuous filling machines, augers, stirrers,hoppers, and post ejection accessories

• Encapsulation filling methods may include powder filling,pellet filling, solid filling, and liquid filling

• Stock for the encapsulation process is supplied from thegranulation process and ingredients/raw materials fromthe dispensing process

• Capsule defects may include short body, short cap, roughcut, collet pinches, punched ends, long body or cap, split,wrinkles, specks, star ends, dirt, strings, bubbles, andprint errors/defects





• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, steam, water, vacuum, gases, and compressedand instrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify productionrequirements for the encapsulation process


• Confirm supply of necessary materials and services to theencapsulation process

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingline clearance and cleaning status and that equipment iscorrectly configured for processing requirements; sensorsand controls are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Verify raw materials with batch instructions• Start, operate, monitor and adjust encapsulation process

equipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• flow rates/quantity• product quality

• Take corrective action in response to out-of-specificationresults This can involve adjusting the flow rates

• Monitor supply and flow of materials to and from theencapsulation process



required to take encapsulation process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility

• Demonstrate batch/product changeovers• Follow end of batch procedures including line clearance








Knowledge of: • Purpose and basic principles of the encapsulationprocess


• Types of raw materials used in the encapsulation processand related handling/segregation requirements. This mayinclude handling hazardous goods

• Stages and changes which occur during encapsulation• Quality characteristics and legal requirements to be

achieved by the encapsulation process• The flow of the encapsulation process and the effect of




• Methods used to monitor the encapsulation process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in theencapsulation process and the related procedures andrecording requirements

• GMP requirements associated with the encapsulationprocess and related control measures




• End-of-batch procedures including procedures forcalculating yield, materials reconciliation and actionrequired if yield/reconciliation is not within prescribedlimits, and product labelling responsibilities andprocedures

• Requirements of different shutdowns as appropriate tothe encapsulation process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage



and performance information




• Environmental issues and controls relevant to theencapsulation process. This includes waste collection andhandling procedures related to the process






Pre-requisite units




• FDFZPRCI2A Operate a process control interface• FDFOPTISP2A Implement sampling procedures• PMLTEST300A Perform basic tests• FDFOPTCRM2A Conduct minor routine maintenance• FDFZCSCIP2A Clean equipment in place• FDFZCSCS2A Clean and sanitize equipment





parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Encapsulation process and related equipment and

services• Materials required for the encapsulation process• Sampling schedules and test procedures and equipment



required





FDFPHFFS2A Operate an aseptic form, fill and seal processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down an aseptic form, fill and sealprocess. This is a primary packaging process to package product intoappropriate packaging.

This unit is based on and equivalent to FDFZPKFFS2A Operate a form,fill and seal process.

Prerequisite Unit(s) FDFZPRCR2A Work in a clean room environmentUnit Sector Pharmaceutical


1. Prepare the forming, fillingand sealing equipmentand process for operation

1.1 Materials and packaging components/consumables areconfirmed and available to meet operating requirements



1.4 Operating parameters are entered as required to meetsafety and production requirements



2. Operate and monitor theforming, filling and sealingprocess




2.4 Packaging quality and seal integrity are monitored toconfirm that specifications are met

2.5 Out-of-specification outcomes are identified, rectifiedand/or reported to maintain the process withinspecification




3. Shut down the forming,filling and sealing process





FDFPHFFS2A Operate an aseptic form, fill and seal process


RANGE STATEMENT





• Forming, filling and sealing equipment and consumablesmay include pumps, aseptic form, fill and seal equipment,aseptic bottle fillers/cappers, hermetic sealers, asepticpackaging, aseptic plastic pouches, and aseptic cartonsystems

• Sterilisation methods used may include use of heat (dryand steam), chemicals (gases and liquids), gammairradiation, and filtration

• Where bottles are formed as part of this process, alsorefer to PMBPROD211A Operate blow mouldingequipment and PMBPROD270A Operate injection blowmoulding equipment

• Work is carried out in a graded clean room environment.Refer to FDFZPRCR2A Work in a clean roomenvironment








EVIDENCE GUIDE



• Select, fit and use personal protective clothing and/orequipment. This includes gowning up, following requiredwork area entry and exit procedures and moving aroundthe work area to minimise risk of contamination

• Confirm supply of necessary packagingcomponents/consumables and product

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;disinfecting and sterilising equipment and surfaces;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured forpackaging requirements; packagingcomponents/consumables are loaded; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Start, operate, monitor and adjust the forming, filling andsealing process equipment to achieve required outcomes.This may include monitoring control points andconducting inspections as required to confirm processremains within specification. This may include monitoring:• container formation• flow rates• weights and volumes• fill levels• temperature - includes materials and sealing

temperatures• supply of packaging components/consumables• packaging quality and seal integrity. This may include

testing packaging integrity• Take corrective action in response to out-of-specification

results• Monitor supply and flow of materials to and from the

process• Respond to and/or report equipment failure within level of


required to take forming, filling and sealing process andrelated equipment off-line in preparation for cleaningand/or maintenance within level of responsibility

• Demonstrate product/process changeovers• Follow end of batch procedures including line clearance


• Complete workplace records as required




Knowledge of: • Purpose and basic principles of forming, filling andsealing. This includes an understanding of the propertiesof packaging materials used, the forming process, andprinciples of heat sterilisation and its effect onmicrobiological characteristics of the product andpackaging materials

• Aseptic container preparation/forming, filling and sealingrequirements

• Basic operating principles of aseptic forming, filling andsealing equipment. This may include an operationalunderstanding of main equipment components, statusand purpose of guards, equipment operating capacitiesand applications, and the purpose and location of sensorsand related feedback instrumentation and servicesrequired for operation of form, fill and seal equipmentused in the workplace

• Quality characteristics and legal requirements to beachieved by the forming, filling and sealing process. Thismay include an understanding of quality requirementspackaging components/consumables, sterilisationrequirements and procedures, container formation, fillingincluding fill levels and weights, and requirements of sealformation and integrity. It may require an understandingof integrity testing procedures

• The flow of processes supplying the forming, filling andsealing process and the effect of process output ondownstream processes





• Common causes of variation and corrective actionrequired. This includes an understanding of the effect ofvariation in both product and packagingcomponents/consumables on filling and sealingperformance. For example, it may include anunderstanding of the effect of temperature variation onthe filling process

• Product/packaging changeover procedures• OHS hazards and controls. This includes awareness of











forming, filling and sealing process. This includes wastecollection and handling procedures related to the process



• Sampling and testing procedures• Routine maintenance procedures


Pre-requisite units

The pre-requisite for this competency standard is:

• FDFZPRCR2A Work in a clean room environment










GMP, quality and environmental requirements, stock flowsystems, production/packaging schedules


• Specifications, control points and operating parameters• Aseptic forming, filling and sealing process and related

equipment and services• Materials and packaging components/consumables to be

formed, filled and sealed• Product• Sampling schedules and test procedures and equipment



required





FDFPHGP2B Operate a granulation processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down the granulation process.Unit Sector Pharmaceutical


1. Prepare the granulationprocess for operation







2. Operate and monitor thegranulation process

2.1 The granulation process is started up and operatedaccording to workplace specifications



2.4 The process is monitored to confirm that granulatedproduct meets specifications





3. Shut down the granulationprocess





FDFPHGP2B Operate a granulation process


RANGE STATEMENT





• Granulation may be a dry or wet process or acombination

• Granulation equipment may include granulators, mixers,blenders, dryers, oscillators, mills, and sieves

• Stock for the granulation process is supplied from thedispensing process and from bulk containers

• Services may include deionised/purified water• Work may involve exposure to dangerous and hazardous

substances• Operation of equipment and processes may require the








EVIDENCE GUIDE


Ability to: • Access workplace information to identify productionrequirements for the granulation process



equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingline clearance and cleaning status; equipment is correctlyconfigured for processing requirements; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Verify raw materials with batch instructions• Start, operate, monitor and adjust granulation process

equipment to achieve required outcomes. This mayinclude interpreting and implementing batch instructions,labelling product, calculating yield, monitoring controlpoints and conducting inspections as required to confirmprocess remains within specification. This may includemonitoring:• granule size• moisture content


• Monitor supply and flow of materials to and from thegranulation process



required to take granulation process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility









Knowledge of: • Purpose and basic principles of the granulation process• Basic operating principles of equipment. This may include


• Types of raw materials used in the granulation processand related handling/segregation requirements. This mayinclude handling hazardous goods

• Stages and changes which occur during granulation• Quality characteristics and legal requirements to be

achieved by the granulation process• The flow of the granulation process and the effect of




• Methods used to monitor the granulation process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the granulationprocess and the related procedures and recordingrequirements

• GMP requirements associated with the granulationprocess and related control measures





• Requirements of different shutdowns as appropriate tothe granulation process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage







granulation process. This includes waste collection andhandling procedures related to the process






Pre-requisite units




• FDFZPRCI2A Operate a process control interface• FDFOPTISP2A Implement sampling procedures• PMLTEST300A Perform basic tests• FDFOPTCRM2A Conduct minor routine maintenance• FDFZCSCIP2A Clean equipment in place• FDFZCSCS2A Clean and sanitize equipment




good manufacturing practice, standard operatingprocedures and environmental requirements


• Production schedule, batch instructions• Specifications, control points and processing parameters• Granulation process and related equipment and services• Materials required for the granulation process• Sampling schedules and test procedures and equipment



required





FDFPHLM2B Operate a liquid manufacturing processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down the liquid manufacturing process.Unit Sector Pharmaceutical


1. Prepare the liquidmanufacturing process foroperation







2. Operate and monitor theliquid manufacturingprocess

2.1 Raw materials are delivered to the process in the requiredquantities and sequence to meet recipe specifications






2.7 The liquid mix is transferred to the required production orstorage location

2.8 Spillages are reported and removed according to standardoperating procedures



3. Shut down the liquidmanufacturing process





FDFPHLM2B Operate a liquid manufacturing process


RANGE STATEMENT





• Liquid manufacturing equipment may include tanks,mixers, homogenisers, thermal jackets, mills, filters,vacuum systems, pumps, stirrers and impellers, purifiedwater systems and materials handling equipment

• Stock for the liquid manufacturing process is suppliedfrom the dispensing process and from bulk containers





• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, steam, water, vacuum, gases, and compressedand instrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify liquidmanufacturing process requirements


• Confirm supply of necessary materials and services to theliquid manufacturing process

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingline clearance and cleaning status; equipment is correctlyconfigured for processing requirements; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Add/load materials in correct quantities and sequence.This may involve monitoring automatic ingredient additionand/or manual addition

• Start, operate, monitor and adjust liquid manufacturingprocess equipment to achieve required outcomes. Thismay include monitoring control points and conductinginspections as required to confirm process remains withinspecification


• Monitor supply and flow of materials to and from the liquidmanufacturing process

• Pace the liquid manufacturing process to meet productionrequirements



required to take liquid manufacturing process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility









Knowledge of: • Purpose and basic principles of the liquid manufacturingprocess. This includes an understanding of thecharacteristics and basic function of raw materials used,and method and sequence of addition required to achieverequired mix characteristics. It may also include anunderstanding of the characteristics of solutions,suspensions and emulsions

• Basic understanding of specific gravity and bulk densityas appropriate for ingredients used

• Basic operating principles of liquid manufacturingequipment. This may include an operationalunderstanding of the main equipment components, statusand purpose of guards, equipment operating capacitiesand applications, the purpose and location of sensors andrelated feedback instrumentation and awareness ofcalibration schedules for scales, and relatedweighing/measuring equipment. It also includesknowledge of services required and action to take ifservices are not available

• Stages and changes which occur during liquidmanufacturing

• Quality characteristics and legal requirements to beachieved by the liquid manufacturing process

• The flow of the liquid manufacturing process and theeffect of outputs on downstream pharmaceuticalprocesses



• Methods used to monitor the liquid manufacturingprocess. This may include inspecting, measuring andtesting as required by the process. It requires awarenessof inspection or test points (control points) in the liquidmanufacturing process and the related procedures andrecording requirements. Monitoring may include• flow rates• materials addition sequence• times/temperatures and agitator speeds• required characteristics of manufactured liquid










• Requirements of different shutdowns as appropriate tothe liquid manufacturing process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage



and performance information• Environmental issues and controls relevant to the liquid

manufacturing process. This includes waste collectionand handling procedures related to the process






Pre-requisite units












parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Liquid manufacturing process and related equipment and

services• Materials required for the liquid manufacturing process• Sampling schedules and test procedures and equipment



required





FDFPHTC2B Operate a tablet coating processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate and shut down the tablet coating process.Unit Sector Pharmaceutical


1. Prepare the tablet coatingprocess for operation

1.1 Tablets and coating materials are confirmed and availableto meet operating requirements






2. Operate and monitor thetablet coating process




2.4 The process is monitored to confirm that coated tabletsmeet specifications

2.5 Spillages are reported and removed according to standardoperating procedures




3. Shut down the tabletcoating process





FDFPHTC2B Operate a tablet coating process


RANGE STATEMENT





• Tablet coating equipment may include coatingpreparation - homogenisers, blenders and mixers, heatexchangers; pumps, jacketed spray guns/heads, coatingpans, polishing pans, holding tanks

• Tablet coating processes may include sugar coating andfilm coating

• Materials used in the sugar coating process includepurified water, cellulose derivatives, polyvinal, gums, andsugar

• Materials used in film coating include purified water andcellulose derivatives





• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, steam, water, vacuum, gasses, and compressedand instrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify tablet coatingprocess requirements


• Confirm supply of necessary tablets, coating materialsand services to the tablet coating process

• Prepare coating materials according to specification• Conduct pre-start checks on coating application

equipment. This may involve inspecting equipmentcondition to identify any signs of wear, selectingappropriate settings and/or related parameters; cancellingisolation or lockouts as required; confirming lineclearance and cleaning status; equipment is correctlyconfigured for processing requirements; sensors andcontrols are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational

• Start, operate, monitor and adjust the tablet coatingprocess equipment to achieve required outcomes. Thismay include monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• pan preparation/coating• coating addition rate• addition/dosing of materials• drying air temperature and flow• addition of polishing agent/gum as required


• Monitor supply and flow of materials to and from thetablet coating process



required to take the tablet coating process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility




May include ability to:• Use process control systems• Collect samples and conduct tests• Conduct routine maintenance




Knowledge of: • Purpose and basic principles of the tablet coatingprocess. This may include an understanding of tabletpreparation/conditioning procedures and requirements,coating preparation and the stages in the coating process


• The flow of the tablet coating process and the effect ofoutputs on downstream pharmaceutical processes

• Stages and changes which occur during tablet coating• Types of materials used in preparation of coatings and

related handling/segregation requirements• Quality characteristics and legal requirements to be

achieved by the tablet coating process• Effect of tablet coating process on the end product• Quality requirements of materials and effect of variation

on tablet coating process performance• Operating requirements and parameters and corrective



• Methods used to monitor the tablet coating process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the tabletcoating process and the related procedures and recordingrequirements

• GMP requirements associated with the tablet coatingprocess and related control measures











and performance information• Environmental issues and controls relevant to the tablet

coating process. This includes waste collection andhandling procedures related to the process






Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Tablet coating process and related equipment and

services• Materials required for the tablet coating process including

tablets and coating materials• Sampling schedules and test procedures and equipment



required




FDFPHTSP2A Operate a terminal sterilisation processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a terminal sterilisation processusing an autoclave. This may be used to sterilise items such as productprior to packing, equipment parts and clothing.




1.1 Items to be sterilised are confirmed and prepared1.2 The autoclave is prepared for operation1.3 Operating parameters are selected as required to meet

safety and terminal sterilisation requirements1.4 Pre-start checks are carried out as required by workplace

requirements1.5 Items are loaded according to load pattern

2. Operate the autoclave toterminally sterilise items

2.1 The autoclave is started and operated according toworkplace procedures

2.2 Time and temperature parameters are monitored toconfirm requirements are met


2.4 Workplace records are maintained according to workplacerecording requirements

3. Remove items and followshut down procedures

3.1 Items are removed from the autoclave according toworkplace procedures




FDFPHTSP2A Operate a terminal sterilisation process


RANGE STATEMENT





• Operation of equipment and processes may require theuse of simple control panels

• Services may need to be confirmed. Typical examplesinclude power, steam, water, vacuum and compressed air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify sterilisationrequirements


• Confirm supply of necessary materials and services.Materials include wrapping material, printed paper rollsand temperature-sensitive tape or other indicator

• Prepare items by wrapping and marking withtemperature-sensitive tape/material. Clothing must befolded correctly

• Load items according to loading pattern• Conduct pre-start checks on the autoclave. This may

involve inspecting equipment condition to confirm that allwater has been drained; pulling a vacuum to remove asmuch air as possible from the autoclave; selectingappropriate settings to meet sterilisation requirements;cancelling isolation or lockouts as required; confirmingthat equipment is clean; sensors and controls arecorrectly positioned and operational, and all safetyguards/signs are in place and operational

• Start, operate and monitor the autoclave to confirm thatthe required outcomes are achieved. This may includemonitoring time, temperature and pressure gauges

• Identify out-of-specification results and take appropriatecorrective action within level of responsibility

• Follow procedures to open autoclave and remove itemsfrom the autoclave to maintain sterility and personalsafety



required to take process off-line in preparation forcleaning and/or maintenance within level of responsibility

• Complete workplace records• Maintain work area to meet housekeeping standards






Knowledge of: • Purpose and basic principles of terminal sterilisation. Thisincludes principles of heat transfer, properties ofsaturated steam, and the relationship between time,temperature and pressure as they affect the kill rate

• The nature of items to be sterilised using an autoclaveand related preparation requirements. This may includean understanding of handling/preparation requirementsfor porous and non-porous loads. It requires anunderstanding of the nature of wrapping materialssuitable for use, the method/s used to wrap items,methods used to monitor that time/temperatureparameters are met - typically heat-sensitive tape ormarkers and the significance of loading patterns inachieving effective sterilisation

• Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents, status and purpose of guards, equipmentoperating capacities and applications, and the purposeand location of sensors and related feedbackinstrumentation. It may require an understanding of thecalibration schedule and procedures to confirm thatinstruments are within calibration. It also includesknowledge of services required and action to take ifservices are not available

• Time/temperature parameters required to achieveterminal sterilisation and corrective action required whereoperation is outside specified operating parameters


• Methods used to monitor the sterilisation process. Thismay include inspecting, measuring and testing asrequired. It requires awareness of inspection or testpoints (control points) and the related procedures andrecording requirements

• Possible causes of variation in outcome and correctiveaction required

• OHS hazards related to autoclave operation andassociated control measures. Hazards typically includeworking with superheated steam and around hotsurfaces, manual handling and steam leaks

• Purpose and limitations of protective clothing andequipment

• Emergency and routine shutdown procedures andprocedures to follow in the event of a power outage


• Procedures and responsibility for recording and reportinginformation on autoclave performance










Pre-requisite units









parameters• Sterilisation schedule/instructions• Specifications, control points and processing parameters• Autoclave equipment and services• Wrapping materials and tape/heat sensitive markers as

required• Items to be sterilised• Materials handling equipment as required• Sampling schedules and test procedures and equipment



required





FDFPLDMP5A Design and maintain programs to supportlegal compliance

Unit Descriptor This unit covers the skills and knowledge required to design, reviewand maintain programs to support policy implementation and regulatorycompliance. Programs involve hazard identification, risk assessmentand control. This applies to areas such as OHS, environmentalmanagement, food safety, quality and GMP. In workplaces whereworkplace programs are already in place, the outcomes of this unit canapply to the assessment and review of such programs.

Unit Sector Planning


1. Establish workplaceprogram and operatingrequirements

1.1 The workplace program reflects workplace policyobjectives

1.2 Roles and responsibilities to support implementation areidentified, negotiated and agreed

1.3 Resources required to support implementation areidentified and secured

2. Establish/reviewconsultative arrangements

2.1 Consultative mechanisms are established to encourageinput from workplace personnel and their representatives

2.2 Information on consultation processes is available,appropriate and accessible

2.3 Procedures are established to ensure that issues raisedare promptly addressed

2.4 Procedures are established to ensure that the outcomesof consultation are promptly communicated

3. Develop/review programprocedures

3.1 Procedures outline the process for identifying andreporting actual and potential hazards

3.2 Risk assessment and control measures are documentedand take account of the hierarchy of control

3.3 Corrective action and emergency response proceduresare defined

3.4 Procedures to review program adequacy andeffectiveness are established

3.5 Program implementation is monitored to ensureprocedures are followed and effective

4. Establish/review programinformation and recordingsystems

4.1 Information is recorded to meet program and legislativerequirements

4.2 Record formats and systems are appropriate andaccessible to users

5. Establish/reviewdevelopment/trainingarrangements to supportprogram implementationand maintenance

5.1 Roles and responsibilities of participants involved inimplementing the program are identified

5.2 Mentoring, coaching and training requirements for eachrole are identified

5.3 Mentoring, coaching and training support is provided tomeet the needs identified


FDFPLDMP5A Design and maintain programs to support legal compliance


6. Maintain a workplaceprogram

6.1 Information on program purpose, requirements, roles andresponsibilities is provided in formats appropriate topurpose and audience

6.2 Program procedures are followed and supervisoryresponsibilities are identified and addressed

6.3 Workplace program records are analysed to identifypatterns of non-conformance and opportunities forongoing improvement

6.4 Hazard identification, risk assessment and control areaddressed when planning, designing and reviewingchange in the workplace

6.5 Evaluation of program effectiveness takes account ofdevelopments in best practice to support continuousprogram improvement

6.6 Program audit procedures are established andcommunicated

RANGE STATEMENT


Range description • Workplace programs are developed to meet companypolicy objectives and are consistent with legislativerequirements, codes, industrial awards and agreements,licensing arrangements and contractual arrangementsand agreements

• Programs and related documentation may be stand-aloneor integrated

• Program design takes account of contextual issuesincluding legislative responsibilities, workplace culture,budgets and people. This includes issues such aslanguage and literacy levels of program users

• Management systems to support program implementationinclude organisational structure, planning activities,responsibilities, practices, procedures, processes andresources for developing, implementing, achieving,reviewing and maintaining the policy, and managing therisks associated with the activities conducted in theworkplace

• Formal responsibility for program design and/or reviewmay be shared with others




EVIDENCE GUIDE


Ability to: • Identify roles and responsibilities for programdevelopment and maintenance. Where appropriate thisincludes negotiating/confirming levels of authority

• Identify and report on resource requirements to supportimplementation. This may include human resources,capital equipment, training, support systems such asmaintenance and financial support. It may also includenegotiating access to resources within level ofresponsibility

• Confirm that personnel involved in implementation havethe required skills and knowledge to carry out their role.This includes identifying and addressing skill gaps

• Review strategies for provision of information to identifyopportunities for improvement in conveying informationappropriate to program requirements and the audience toensure that information is accessible to andunderstandable by all employees

• Establish and/or review consultative arrangements toconfirm that they are effective channels of two-wayinformation and forums for raising issues and generatingideas; that all areas and levels of the workgroup haveopportunity for input; and there is feedback to contributorson the outcome of consultation

• Develop/review procedures to support implementation.Procedures must be documented and documents mustbe controlled. This may require the development of anappropriate system for recording and managingprocedures

• Establish/review monitoring mechanisms to ensure thatrecords are accurate and timely

• Establish/review procedures to ensure that records andrelated program information are utilised to supportprogram improvement

• Trial/review implementation of procedures and identifyopportunities for improvement




Knowledge of: • Objectives of legislation, regulations and relevant codesof practice relating to the program area. This includes anunderstanding of the roles of relevant regulatory bodies

• Company policy objectives, related legal requirementsand workplace context. This includes an understanding ofresource capacity, authority levels, existing systems andprocesses such as consultation processes,development/training systems, process improvement,document control and recording requirements

• Workplace program objectives, their relationship to policyobjectives and to related programs. This includes anunderstanding of the benefits of the program for thecompany, employees and the wider community asappropriate

• The concept of a management systems as it applies tothe program area

• The advantages and disadvantages of stand-alone andintegrated programs. This includes an understanding ofthe variations in legal obligations and compliancesystems, objectives and structure of related policies andprograms and may include consideration of audit trails asappropriate

• Principles and processes for hazard identification, riskassessment and control. This requires current technicalknowledge of the program area and/or a knowledge ofinternal and external experts and resources to supportdesign and implementation

• The circumstances, conditions or practices likely to resultin program non-compliance and related control options

• Communication skills to support a review of existinginformation and/or design of information formats to meetprogram and audience requirements

• Technical knowledge and/or access to technical expertiseto ensure adequacy of risk control methods and responseto non-compliance/emergencies

• Problem solving and process improvement techniquesand processes

• Program review methods and responsibilities. Thisincludes an understanding of internal audit arrangementsand may include an understanding of external auditarrangements. Where the program supports legalcompliance obligations, it includes an understanding ofrequirements and frequency of audits





Pre-requisite units

The relevant unit for the program area is the pre-requisite forthis competency standard. This may include:

• FDFCORQFS3A Monitor the implementation of qualityand food safety programs

• FDFPMOHS4A Manage the implementation ofoccupational health and safety policies and procedures inthe workplace

• FDFOPTHCP3A Participate in a HACCP team• FDFTECENV4A Manage the implementation of

environmental management policies and procedures inthe workplace



• FDFOPTSM3A Support and mentor individuals andgroups

• BSBCMN405A Analyse and present research information• BSBFLM510A Facilitate and capitalise on change and

innovation• FDFIMMIA4A Manage internal audits



• Workplace policies, business and performance plans andbudgets

• Relevant legislation, codes of practice and agreements• Workplace procedures and related management systems

relevant to the program area• Technical support and advice as appropriate to the

program area• Consultative forums





FDFPLPCM4A Plan and co-ordinate maintenanceUnit Descriptor This unit covers the skills and knowledge required to plan and

co-ordinate maintenance of production equipment. This competency isappropriate for production management personnel. It does not requirethat the person who co-ordinates maintenance is also responsible forconducting maintenance.



1. Identify maintenancerequirements

1.1 The approach to maintaining production equipment isidentified

1.2 Advice on equipment maintenance requirements isidentified and assessed

1.3 Special maintenance requirements are assessed andprioritised

2. Plan maintenance 2.1 Resources required to carry out maintenance areidentified and secured

2.2 A maintenance schedule is developed to provide reliableequipment performance with minimal disruption toproduction

2.3 The maintenance schedule takes account of productionschedules, equipment capability, special maintenancerequirements and efficient resource utilisation

2.4 The maintenance schedule is recorded in the appropriateworkplace format

2.5 Responsibilities for implementing the maintenanceschedule are defined and communicated

2.6 Work areas and personnel affected by the maintenanceprogram are consulted and advised of maintenanceprogress

3. Monitor implementation ofthe maintenance schedule

3.1 Progress of maintenance is monitored to identify varianceto schedule

3.2 Unplanned events that could affect the schedule areidentified, assessed and addressed

3.3 Potential failure to meet maintenance deadlines areidentified and communicated to relevant personnel in atimely manner

4. Contribute to theimprovement ofequipment reliability

4.1 Equipment performance information is reviewed to identifypatterns or trends

4.2 Factors that affect equipment reliability are identified4.3 Production and maintenance personnel are consulted to

identify opportunities to improve equipment reliability4.4 Action is taken to improve equipment reliability4.5 The maintenance schedule and related programs and

procedures are reviewed to reflect improvements


FDFPLPCM4A Plan and co-ordinate maintenance


RANGE STATEMENT


Range description • Maintenance scheduling and work practices areconsistent with company policies and procedures,regulatory and licensing requirements, legislativerequirements, and industrial awards and agreements andtakes account of OHS and environmental impact ofscheduling arrangements

• Scheduling may involve the use of planning and systemscontrol software such as SAP and MRPII

• Maintenance schedules may relate to lubricationschedules, service schedules and major cleaning wherecleaning requires equipment dismantling or strip down

• Co-ordination may involve the management of contractswith external maintenance service providers and/orinternal maintenance personnel




EVIDENCE GUIDE


Ability to: • Describe the company's approach to equipmentmaintenance

• Collect information on equipment maintenancerequirements. Typical sources of information includemanufacturers' specifications, equipment capability data,condition monitoring data, equipmentoperation/performance reports and log sheets.Information is assessed to identify routine lubrication andservicing requirements as appropriate

• Analyse equipment maintenance data. This may includethe use of data analysis techniques to plot and interprettrends and patterns in equipment performance

• Identify components of the maintenance program andrelated responsibilities for implementation. This mayinclude equipment monitoring, lubrication schedules,routine servicing and cleaning schedules and breakdownor emergency response. Implementation is typicallyshared between production and maintenance personneland/or external service providers. Relative responsibilitiesare clearly defined

• Identify and confirm resource requirements to meetmaintenance requirements. This requires anunderstanding of the nature of maintenance tasksinvolved to identify the required maintenance equipment,materials/consumables and competencies. It may alsoinvolve identifying and liaising with external maintenanceservice providers

• Confirm that personnel with the required competenciesare available to conduct maintenance activities. This mayinvolve reporting and/or developing competenciesrequired to implement the maintenance schedule. It mayalso involve managing contracts with maintenanceproviders

• Develop a schedule for equipment maintenance tosupport reliable equipment performance with minimaldisruption to production. This includes consulting relevantpersonnel to confirm schedule feasibility; and notifyingrelevant personnel of any possibility that maintenancecannot be completed within scheduled timeframe

• Record and communicate the schedule in appropriateformats. This may involve use of software, andcommunicating information to meet workplace andaudience requirements

• Ensure that operating procedures are available andinclude information on OHS, environmental managementand food safety requirements and responsibilities

• Monitor maintenance activities against the schedule toidentify variances and take appropriate corrective action.Corrective action involves assessing the consequences of




any adjustments to the schedule. It may also involvemonitoring that maintenance is completed withinmaintenance budget constraints

• Respond to unplanned events such as major equipmentbreakdowns to minimise disruption and optimiseefficiency

• Communicate maintenance requirements and reportoutcomes. This includes ensuring effectivecommunication between production and maintenancepersonnel to enhance equipment reliability and identifyimprovement opportunities


• Use planning and systems control software




Knowledge of: • Basic maintenance approaches and differences betweenreactive, preventative and proactive maintenance modelssuch as reliability centred maintenance (RCM) and totalproductive maintenance (TCM)

• Company systems, processes and responsibilities forcollecting equipment condition information, analysinginformation and carrying out required servicing andmaintenance tasks

• Sources of data on equipment performance andmaintenance requirements, related recording systemsand data analysis tools

• The requirements of the maintenance schedulingprocess. This includes an understanding of the productionprocess to identify the impact of scheduling on productionin order to oversee maintenance activities and establishmaintenance priorities

• Link to related activities such as purchasing and contractmanagement

• Factors that influence the reliability of equipment. Thisincludes equipment capability, equipment/process design,and operating conditions and practices

• Methods used to measure effectiveness of maintenanceincluding measures of plant availability, cost ofmaintenance, downtime, and alternate resource utilisation

• OHS, environmental and food safety requirements andresponsibilities associated with maintenance activities

• Relevant personnel and departments to beconsulted/notified of maintenance schedule and relatedamendments. This includes an understanding of theinformation relevant to each group/person

• Awareness of conditions that can affect achievement ofthe maintenance schedule. This includes conditions thatare unusual or unplanned, and related options forresponse to equipment breakdowns/emergencies


• Recording systems and requirements. This includesknowledge of relevant software packages

• Process improvement procedures


• Maintenance service supplier capacity





Pre-requisite units




• FDFIMMWB4A Manage a work area within budget• FDFPLSCP4A Schedule and manage production• BSBCMN405A Analyse and present research information



• Maintenance scheduling system and associatedinformation and communication systems

• Production equipment• Relevant standard operating procedures• Workplace information recording systems, requirements

and procedures





FDFPLSCP4A Schedule and manage productionUnit Descriptor This unit covers the skills and knowledge required to plan, monitor and

adjust schedules to meet operational requirements. This competency isappropriate for production personnel with some responsibility forplanning.



1. Identify productionrequirements

1.1 Forecast and sales information is used to identifyproduction requirements

1.2 Production priorities are identified to satisfy demand

2. Identify resourcerequirements to meetproduction requirements

2.1 Stock levels of raw materials/ingredients, packagingcomponents and consumables are confirmed againstproduction requirements

2.2 Equipment capacity and status and human resources areconfirmed against production requirements

3. Develop andcommunicate theproduction schedule

3.1 The production schedule is developed to meet demandand delivery timelines within production capacity andbudget

3.2 The production schedule takes account of stock levels,storage capacity, equipment capacity and product mix tominimise stock and product holdings and maximiseproduction efficiency

3.3 The production schedule is recorded in the appropriateworkplace format

3.4 The production schedule is made available to relevantpersonnel in a timely manner

4. Monitor actual againstscheduled production

4.1 Production is monitored to identify actual and potentialbarriers to achieving the schedule

4.2 Resource usage rates are monitored to identify potentialshortages

4.3 Unplanned events that could affect the schedule areidentified, assessed and addressed

5. Adjust productionschedules

5.1 Production schedules are adjusted to take account ofchanged conditions

5.2 Changes to the production schedule are negotiated andcommunicated to relevant personnel in a timely manner

5.3 Resource implications of amended schedules areidentified and resources are accessed to meetrequirements

5.4 Potential failure to meet delivery deadlines are identifiedand communicated to relevant personnel in a timelymanner

5.5 Schedule documentation is amended as required to meetworkplace reporting requirements


FDFPLSCP4A Schedule and manage production


6. Review productionschedule developmentprocess

6.1 The production scheduling process is reviewed to identifyopportunities for improvement

6.2 Variances in production against schedule are identified,investigated and reported

6.3 Personnel responsible for implementing the schedule areconsulted to identify improvement opportunities

6.4 The scheduling process is revised to reflect improvements

RANGE STATEMENT


Range description • Production scheduling is consistent with company policiesand procedures, regulatory and licensing requirements,legislative requirements, and industrial awards andagreements and takes account of OHS andenvironmental impact of scheduling arrangements

• Scheduling may involve the use of planning and systemscontrol software such as SAP and MRPII

• Production schedules may relate to daily, weekly and/ormonthly production

• Schedules may be based on customer orders and/ormarket forecasts




EVIDENCE GUIDE


Ability to: • Collect and interpret sales and/or market forecastinformation. This may involve liaising with salesdepartments/functions and/or direct contact withcustomers

• Identify production priorities to meet customer/marketexpectations

• Identify and confirm resource requirements to meet theschedule. This may include stock levels, equipmentavailability and capacity, personnel, storage capacity, andtransport. This may include identifying alternate sourcesof supply for resources in short supply

• Develop a schedule to match production priorities toavailable resources. This includes consulting relevantpersonnel to confirm schedule feasibility; and notifyingrelevant personnel of any possibility that demand cannotbe met within required timeframe

• Record and communicate the schedule in appropriateformats. This may involve use of software andcommunicating information to meet workplace andaudience requirements

• Monitor actual production and materials usage levelsagainst production plan to identify variances and takeappropriate corrective action. Corrective action involvesassessing the consequences of any adjustments to theschedule for the customer, the company and resourceavailability

• Adjust the schedule in response to typical and atypicalvariables affecting achievement of schedule

• Respond to unplanned events to minimise disruption andoptimise efficiency

• Confirm that resources and personnel are available tomeet amended schedule and, if not, take action to securerequirements

• Communicate schedule changes to affected personnel• Track and investigate variance to identify cause• Follow review procedures to identify opportunities to

improve scheduling process• Follow procedures to adopt and communicate

improvements to the scheduling process


• Use planning and systems control software• Match work allocation to competencies available in the

work team




Knowledge of: • The role and scope of the scheduling function. Thisincludes an understanding of flow of information to andfrom the scheduling process and the impact of schedulingfor related planning, purchasing, production and despatchprocesses

• Factors to be taken into account in planning the scheduleincluding the inter-relationships between factors. Factorstypically include but are not limited to:• customer requirements• stock levels and supply options• use-by codes• production capacity and availability• labour requirements and availability• product compatibility• capacity of related processes and/or storage facilities• transport capacity

• Consequences of failing to meet delivery timelines. Thismay differ according to customers and may includestock-out fines in addition to damage to customerrelationships. It also includes an understanding of thecompany's preferred approach to managing customerrelations

• Knowledge of the characteristics of rawmaterials/ingredients, packaging components andconsumables and production process to determine themost efficient plan to meet production requirements. Thisincludes an understanding of stock shelf-life, productcompatibility (with the exception of dedicated productlines) and changeover procedures

• Knowledge of equipment capacity to ensure thatproduction quantities and timelines are achievable

• Methods used to monitor actual to planned production.This may include use of systems software and KeyPerformance Indicators KPIs where these are collectedon a real time basis

• Relevant personnel and departments to beconsulted/notified of production schedule and relatedamendments. This includes an understanding of theinformation relevant to each group/person

• Awareness of conditions that can affect achievement ofschedule. This includes conditions that are unusual orunplanned and related options for response

• Options for maximising resource utilisation andminimising waste. This includes options for alternateresource allocation in response to unplanned events


• Recording systems and requirements• Process improvement procedures


• Supplier capacity and timeframes• Competencies required by the work process and




competencies held by the work team


Pre-requisite units




• FDFIMMWB4A Manage a work area within budget• BSBCMN405A Analyse and present research information



• Scheduling system and associated information andcommunication systems

• Production area and related functions and resources• Relevant standard operating procedures• Workplace information recording systems, requirements

and procedures




FDFPBBDM3A Operate a dough mixing processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down the process used to make updough. This includes selecting and mixing dough ingredients.

Unit Sector Plant Baking Bread


1. Prepare the dough makingequipment and processfor operation

1.1 Ingredients are weighed or measured to meet reciperequirements


1.3 Materials handling, mixing/blending equipment and relatedattachments are fitted and adjusted to meet operatingrequirements




2. Operate and monitor thedough mixing process


2.2 Ingredients are introduced to the mixing process in correctsequence and quantity



2.5 The process is monitored to confirm that dough meetsspecifications


2.7 The finished dough is transferred to required location2.8 The workplace meets housekeeping standards2.9 Workplace records are maintained according to workplace


3. Shut down the process 3.1 The appropriate shutdown procedure is identified3.2 The process is shut down and cleaned according to

workplace procedures3.3 Maintenance requirements are identified and reported



FDFPBBDM3A Operate a dough mixing process


RANGE STATEMENT





• Equipment may include mixers, scales, grain conditionersand materials handling equipment. Materials are typicallydelivered to the mixer via operation of bulk materialshandling systems. Non-bulk ingredients may be dosedautomatically or manually loaded



• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, water, and compressed and instrumentation airand refrigerant

• Note that this unit duplicates the outcomes of unitFDFZPRIPK3A Apply raw materials/ingredient andprocess knowledge. Only one of these units can becounted towards a qualification outcome. For furtherinformation refer to advice on unit duplication in thesection on qualification arrangements




EVIDENCE GUIDE


Ability to: • Access workplace information to identify recipe and batchrequirements


• Confirm supply and condition of necessary ingredientssuch as flour and supply of services

• Load materials in correct quantities and sequenceaccording to company procedures

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat related equipment is clean and correctly configuredfor dough making requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational. Specific settings may include:• mixing rate• mixing time/work input• ice/water requirements• water temperature• speed• flour temperature• cooling• vacuum delay and level• slurry addition

• Start, operate, monitor and adjust dough makingequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. This includes monitoring doughconsistency, temperature, development and timeliness

• Adjust yeast levels to allow for rework addition andambient temperature

• Monitor supply and flow of materials to and from thedough making process



• Locate emergency stop functions on equipment• Demonstrate batch/product changeovers• Follow isolation and lock out/tag out procedures as

required to take dough making process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility

• Complete workplace records as required• Clean and sanitize equipment• Maintain work area to meet housekeeping standards




Knowledge of: • Purpose and basic principles of the dough makingprocess. This includes an understanding of thecomponents of wheat, flour types and grades relevant toproducts produced, yeast activity and dough development


• The flow of the dough making process, including thestages and changes which occur during baking, and theeffect of outputs on downstream processes

• Ingredient characteristics, and condition requirementsand purpose in the dough and the finished product

• Significance of factors such as dough temperature,development, water addition/temperature, yeast activityand consistency of dough

• Required characteristics of dough and effect of doughcharacteristics/variation on the final product

• Quality requirements of materials and effect of variation iningredient quality on the dough. This includes anunderstanding of the impact of variation in flour quality

• Stock management procedures. This includes anunderstanding of stock rotation and use-by codes



• Methods used to monitor the dough making process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the doughmaking process and the related procedures and recordingrequirements

• Ingredient/materials handling and storage requirements• Contamination/food safety risks associated with the

dough making process and related control measures• Common causes of variation and corrective action

required• OHS hazards and controls• Requirements of different shutdowns as appropriate to

the dough making process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage







• Cleaning and sanitation procedures• Environmental issues and controls relevant to the dough

making process. This includes waste/rework collectionand handling procedures related to the process






Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Dough mixing process and related equipment and

services• Ingredients to be processed• Sampling schedules and test procedures and equipment



required




FDFPBBFP3A Operate a final proof and baking processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down the process used to carry out thefinal proofing and baking of dough. This includes depanning the bakedproduct.



1. Prepare the final proofingand baking equipment andprocess for operation

1.1 Dough is supplied to the final proofer to meetproduction/batch requirements






2. Operate and monitor thefinal proofing and bakingprocess




2.4 The process is monitored to confirm that baked productmeets specifications




3. Shut down the finalproofing and bakingprocess

3.1 The appropriate shutdown procedure is identified3.2 The process is shut down and cleaned according to




FDFPBBFP3A Operate a final proof and baking process


RANGE STATEMENT





• Equipment may include final proofers and industrial ovens• Operation of equipment and processes may require the



• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, steam, water, gas, and compressed andinstrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify final proof andbaking processing requirements



equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat related equipment is clean and correctly configuredfor final proof and baking process requirements; sensorsand controls are correctly positioned; any scheduledmaintenance has been carried out, and that all safetyguards are in place and operational. Specific settings mayinclude:• final proofer time, temperature, humidity and loading

arm position• topping application equipment, water sprays and

splitters for finishing equipment• oven time, temperature, lid positions, conveyors,

loaders and dischargers, circulation and exhaust fans,burner controls and steam settings

• depanning equipment heights, tin guides and airblowers and pre-blast conveyor settings

• Start, operate, monitor and adjust final proof and bakingprocess equipment to achieve required outcomes. Thismay include monitoring control points and conductinginspections as required to confirm process remains withinspecification:• for final proof, this may include dough condition/surface

and dough size/height• for finishing/topping, this may include

coverage/distribution of topping and visual inspectionof appearance

• for baking, this may include crust colour, sheen,uniformity of shape, weight and size

• for the depanning unit, this may include bread iscleanly removed from the pan

• Monitor supply and flow of materials to and from the finalproof and baking process




required to take final proof and baking process andrelated equipment off-line in preparation for cleaningand/or maintenance within level of responsibility




• Demonstrate batch/product changeovers• Clean and sanitize equipment• Complete workplace records as required• Maintain work area to meet housekeeping standards






Knowledge of: • Purpose and basic principles of each stage of the finalproof and baking process


• The flow of the final proof and baking process and theeffect of outputs on downstream processes

• Changes that occur in dough during baking. This includesstarch gelatinisation, gluten coagulation and enzymeactivity, and their effect on the final product

• The effect of process variables such as time, temperatureand humidity on process stages

• The effect of yeast activity on the end product• Quality characteristics to be achieved by the final proof

and baking process. This includes factors influencingcrust formation and colour

• Quality requirements of materials and effect of variationon final proof and baking process performance



• Methods used to monitor the final proof and bakingprocess. This may include inspecting, measuring andtesting as required by the process. It requires awarenessof inspection or test points (control points) in the finalproof and baking process and the related procedures andrecording requirements

• Contamination/food safety risks associated with the finalproof and baking process and related control measures

• Batch/product changeover requirements• Common causes of variation and corrective action

required• OHS hazards and controls. This includes awareness of


• Requirements of different shutdowns as appropriate tothe final proof and baking process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage







• Cleaning and sanitation procedures• Environmental issues and controls relevant to the final

proof and baking process. This includes waste/reworkcollection and handling procedures related to the process






Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Final proofing, baking and depanning process and related

equipment and services• Panned dough• Dough transfer equipment• Sampling schedules and test procedures and equipment



required




FDFPBBMU3A Operate a dough make up processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down the process used to make updough. This includes dividing and rounding, intermediate proving,moulding and panning.



1. Prepare the divider,rounder, moulder andpanning equipment andprocess for operation

1.1 Dough is confirmed and available to meet operatingrequirements






2. Operate and monitor thedough make up process




2.4 The process is monitored to confirm that dough piecesmeet specifications




3. Shut down the doughmake up process





FDFPBBMU3A Operate a dough make up process


RANGE STATEMENT





• Equipment may include dividers, rounders, intermediateprovers, moulders, panners and materials handlingequipment



• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, oil (for the divider) and compressed andinstrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify dough make upprocessing requirements



equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat related equipment is clean and correctly configuredfor processing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational. Pre-start checks may includeconfirming/setting:• divider speed, weight setting and oil supply• air flow from fans in rounder• intermediate proving process airflow and dusting as

required• moulding process settings, including sheeting, sealing

board height and width, four piecing and rolleradjustments

• panning process settings, including side guides,sealing board, knives, folders and side belts

• confirming supply of pans, oiling pans as required andsetting pan stops and guides for panning unit

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required toconfirm process remains within specification. Monitoringmay include:• dough height in hopper• dough weight• oil flow to divider• size and shape of dough piece• skin formation during intermediate proof• presence of 'doubles'• process variables such as time, temperature and

humidity• Monitor supply and flow of materials to and from the

process• Take corrective action in response to out-of-specification


responsibility• Locate emergency stop functions on equipment• Demonstrate batch/product changeovers• 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 levelof responsibility

• Clean and sanitize equipment• Complete workplace records as required• Maintain work area to meet housekeeping standards


1 Use process control systems2 Collect samples and conduct tests3 Conduct routine maintenance




Knowledge of: • Purpose and basic principles of each stage of the doughmake up process


• The flow of the dough make up process and the effect ofoutputs on downstream processes

• The effect of process variables such as time, temperatureand humidity on process stages

• The effect of process stages such as moulding on doughstructure

• Quality characteristics to be achieved by the dough makeup process

• Quality requirements of materials and effect of variationon the dough make up process performance

• Operating requirements and parameters and correctiveaction required where operation is outside specifiedoperating parameters. This includes an understanding ofprocedures for rework addition


• Methods used to monitor the dough make up process.This may include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the doughmake up process and the related procedures andrecording requirements

• Contamination/food safety risks associated with thedough make up process and related control measures



the dough make up process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage

• Cleaning methods and procedures• Isolation, lock out and tag out procedures and

responsibilities• Cleaning and sanitation procedures• Product/process changeover procedures and


and performance information• Environmental issues and controls relevant to the dough

make up process. This includes waste/rework collectionand handling procedures related to the process









Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Dough make up process and related equipment and

services• Dough transfer equipment• Dough to be processed• Sampling schedules and test procedures and equipment



required





FDFPBSW2B Operate a cooling, slicing and wrappingprocess

Unit Descriptor This is a Specialist unit. It covers the skills and knowledge required toset up, operate, adjust and shut down a bread cooling, slicing andwrapping process.



1. Prepare the cooling,slicing and wrappingequipment and processfor operation

1.1 Baked product and packaging consumables are confirmedand available to meet operating requirements






2. Operate and monitor thecooling, slicing andwrapping process

2.1 The cooling, slicing and wrapping process is started andoperated according to workplace procedures



2.4 The process is monitored to confirm that product is cooledand packaged to meet specifications




3. Shut down the cooling,slicing and wrappingprocess





FDFPBSW2B Operate a cooling, slicing and wrapping process


RANGE STATEMENT





• Equipment may include materials transfer equipmentsuch as conveyors and trolleys, cooler, slicer, baggingand bag closing equipment, metal detector and scales







EVIDENCE GUIDE




• Confirm supply of necessary product, packagingconsumables and services

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured forprocessing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational. Settings in the cooler may include:• conveyor speed/track position• humidity• air flow/fan settings• product layout/spacing

• Settings in the slicing/bagging equipment may include:• knife condition• machine speed• height/width settings• air pressure• bag/tag type and coding

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required toconfirm process remains within specification

• Monitor supply and flow of product and packagingconsumables to and from the process











Knowledge of: • Purpose and basic principles of the cooling, slicing andwrapping process


• The flow of this process and the effect of outputs ondownstream processes and final product

• Quality characteristics to be achieved by the process• Quality requirements of packaging materials and effect of

variation on process performance and product shelf-life• Operating requirements and parameters and corrective



• Methods used to monitor the cooling, slicing and baggingprocess. This may include inspecting and measuring asrequired by the process. It requires awareness ofinspection or test points (control points) in the processand the related procedures and recording requirements




• Requirements of different shutdowns as appropriate tothe process and workplace production requirements












Pre-requisite units




• FDFZPRCI2A Operate a process control interface• FDFOPTCRM2A Conduct routine maintenance• FDFZCSCS2A Clean and sanitize equipment





parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Cooling, slicing, bagging and related equipment and

services• Product and packaging consumables• Documentation and recording requirements and


required





FDFPBW1A Participate effectively in a workplaceenvironment (plant baking)

Unit Descriptor This is a Specialist unit. It covers the skills and knowledge required toparticipate effectively in a plant baking workplace.



1. Carry out responsibilitiesin accordance withworkplace policies andprocedures

1.1 Information on conditions of employment, companypolicies and procedures are identified

1.2 Policies and procedures are applied when carrying outwork role

2. Identify and locatecompany product andprocesses

2.1 Company product range is identified2.2 Production/packaging stages and processes carried out

on site are identified and located

RANGE STATEMENT


Range description • Work is carried out in accordance with company policiesand procedures, regulatory and licensing requirements,legislative requirements, and industrial awards andagreements.

• Company policies and procedures referred to areadditional to those covered by OHS, quality, food safetyand environmental competency standards. They includecodes of practice and general employment policies andprocedures in areas such as sexual harassment,EEO/affirmative action, anti-discrimination, racialvilification and workplace bullying

• Conditions of employment typically include pay andconditions, leave arrangements; reporting andtimekeeping responsibilities; terms of employmentincluding permanent, casual and probationary periods;disciplinary procedures; staff facilities and amenities

• Key personnel may include but are not limited to HRpersonnel responsible for recruitment, training, pay andconditions issues; relevant site and operations managers;supervisors/team leaders; and industrial/work arearepresentatives


FDFPBW1A Participate effectively in a workplace environment (plant baking)


EVIDENCE GUIDE


Ability to: • Identify and access information on conditions ofemployment and workplace policies and procedures.Information may be provided in print, audio-visual and/orverbal formats

• Locate workplace amenities and facilities relevant to workresponsibilities

• Identify and locate materials/storage areas in theworkplace, relevant to work role. This may includelocating bulk storage areas and identifying specialstorage conditions such as hazardous goods andtemperature controlled stores areas

• Identify and locate plant baking production, cooling,slicing and wrapping, and packing processes/main workareas in the workplace

• Model appropriate behaviour when interacting with othersand moving around the workplace

Knowledge of: • Workplace structure and key personnel• Rights and responsibilities of employees as defined in

employment conditions• Company policies and procedures relating to work

responsibilities. This includes awareness of areascovered by legislation and related responsibilities

• Appropriate personal conduct in a work area. Thisincludes minimum clothing and personal hygienestandards when entering and moving around a foodprocessing area in order to protect both employees andproduct safety. It also covers appropriate behaviourtowards others in the work area

• Industrial representation arrangements• Site security arrangements. This includes awareness of

responsibility to report when coming on- and off-site• Site layout. This includes main facilities such as

canteens, parking areas, storage areas, processing andpacking areas and location of emergency exits andassembly areas

• The main products/product range produced in theworkplace

• Stages and processes used to manufacture and packagebaked bread products

• Personal reporting roles and responsibilities





Pre-requisite units





Assessment must occur in a real workplace where theassessee has access to:

• Advice on work roles and responsibilities• Advice on workplace policies, codes of practice,

procedures, structure and personnel• Advice on conditions of employment and entitlements• Site maps• Workplace access





FDFPOAC2A Operate an automated cutting processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down an automated cutting process.Unit Sector Poultry


1. Prepare the automatedcutting equipment andprocess for operation

1.1 Carcasses/pieces are confirmed and available1.2 Cleaning and maintenance requirements and status are


and adjusted to meet safety, bird type/size and cuttingrequirements



2. Operate and monitor theautomated cutting process

2.1 Carcasses/pieces are inspected to confirm that qualityrequirements are met

2.2 Carcasses/pieces are hung to meet production pace2.3 Equipment is monitored to identify variation in operating



2.5 Quality and accuracy of cuts is monitored to confirm thatspecifications are met

2.6 Out-of-specification outcomes are identified, rectifiedand/or reported to maintain the process withinspecification



3. Shut down the automatedcutting process





FDFPOAC2A Operate an automated cutting process


RANGE STATEMENT





• Production equipment may include dedicated singleand/or multiple cutting equipment, shackles and conveyorsystems




• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, water and instrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify cuttingrequirements


• Confirm supply of necessary carcasses/pieces andservices. This includes inspecting and removingcarcasses/pieces of unacceptable quality

• Conduct pre-start checks. This may involve inspectingequipment condition to identify blade sharpness and othersigns of wear; selecting appropriate settings and/orrelated parameters according to bird size/type; cancellingisolation or lockouts as required; and confirming thatequipment is clean and correctly configured for cuttingprocess requirements; sensors and controls are correctlypositioned; any scheduled maintenance has been carriedout, and that all safety guards are in place andoperational. It may also include running trial cut to confirmaccuracy/positioning

• Start, operate, monitor and adjust automated cuttingprocess equipment to achieve required outcomes. Thisincludes hanging carcasses/pieces to meet productionpace and may include monitoring control points andconducting inspections as required to confirm cutaccuracy within specification

• Monitor supply and flow of carcasses/pieces to and fromthe automated cutting process

• Take corrective action in response to out-of-specificationresults. This includes adjusting blades/knives within levelof responsibility


• Demonstrate procedure to adjust equipment forbird/portion type/size


required to take automated cutting process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility



• Use process control systems• Conduct routine maintenance such as blade replacement• Clean and sanitize equipment




Knowledge of: • Purpose and basic principles of the automated cuttingprocess


• The flow of the automated cutting process and the effectof outputs on downstream processes

• Quality characteristics to be achieved by the automatedcutting process. This includes knowledge of qualityspecifications and ability to assess cut quality anddetermine any required adjustments



• Methods used to monitor the automated cutting process.This includes inspecting the quality of cuts. It requiresawareness of inspection or test points (control points) inthe automated cutting process and the related proceduresand recording requirements. This may include recordinginformation such as temperatures and product codes

• Contamination/food safety risks associated with theautomated cutting process and related control measures



• Requirements of different shutdowns as appropriate tothe automated cutting process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage



• Environmental issues and controls relevant to theautomated cutting process. This includes waste/reworkcollection and handling procedures related to the process








Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Automated cutting process and related equipment and

services• Carcasses/pieces to be processed• Documentation and recording requirements and


required





FDFPOCWS3A Operate a chickway systemUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

plan, set up and operate a carcass delivery system to deliver birds tothe packaging area to meet production orders.

Unit Sector Poultry


1. Prepare the chickwaysystem for operation

1.1 Identify, select and load program into computer to suitproduct

1.2 Control line startup1.3 Identify bird drop requirements1.4 Set system to meet production requirements

2. Monitor system operation 2.1 Enter new orders and set system parameters to meetrequirements through the day

2.2 Adjust priorities to meet production and customerrequirements

2.3 Monitor weight ranges and adjust system settings to meetcustomer orders


2.5 The system is monitored to confirm that specifications aremet

2.6 Out-of-specification process outcomes are identified,rectified and/or reported to maintain the process withinspecification

3. Handover systemoperation

3.1 Workplace records are maintained according to workplacerecording requirements

3.2 Handover is carried out according to workplaceprocedures

3.3 Process operators are aware of system and relatedequipment status at completion of handover

4. Shut down the system 4.1 The appropriate shutdown procedure is identified4.2 The system is shut down according to workplace


5. Contribute to continuousimprovement of thesystem

5.1 System performance is reviewed against outputplan/targets

5.2 Opportunities for system improvement are identified andinvestigated

5.3 Proposals for improvements are developed andimplemented within company planning arrangements andaccording to company procedures


FDFPOCWS3A Operate a chickway system


RANGE STATEMENT


Range description • Work is carried out according to company procedures,regulatory and licensing requirements, legislativerequirements, and industrial awards and agreements

• Legislative requirements are typically reflected inprocedures and specifications. Legislation relevant to thisindustry includes the labelling, weights and measureslegislation; and legislation covering food safety,environmental management, occupational health andsafety, anti-discrimination and equal opportunity

• Workplace information may include Standard OperatingProcedures (SOPs), specifications, kill plan, customerorders, performance records and reports

• Chickway system operation typically involves planning,co-ordination and troubleshooting within level of authority.System operation may involve co-ordination of otheroperators

• A chickway system involves use of a computer to controlthe conveyor system that delivers birds of a given size,weight and grade to the required locations for packing orfurther processing

• Handovers may be done in person or viarecording/communication systems as required byworkplace arrangements

• Operation and monitoring of equipment and systemprocesses requires the use of control panels and systems




EVIDENCE GUIDE


Ability to: • Access kill plan, customer orders and related informationto plan order priorities

• Select and load required program• Apply basic standard deviation to analyse weight

distribution of flock• Operate control system to start conveyors• Confirm that birds available match production order

requirements• Select system settings to deliver birds of required weight,

type, grade and number to required production areas atthe time required

• Modify system parameters to respond to operatingconditions and bird supply

• Monitor system operation. This may include monitoring:• timely flow and delivery of birds to meet production

requirements• pace of delivery to production area to match work flow• system alarms• weight ranges to confirm match with delivery

requirements• Liaise with relevant departments to respond to customer

requirements• Identify out-of-specification performance and take

corrective action. This can include responding toout-of-specification weight, drop position and sensorerrors

• Demonstrate system shutdown procedure• Monitor operating efficiencies of the system and

investigate, resolve and/or report problems• Report on system performance as required by workplace

reporting arrangements• Conduct computer system maintenance as required to

clear computer for new start




Knowledge of: • System configuration. This includes an understanding ofsystem flow, layout and drop points

• Customer ordering procedures. This includes anunderstanding of common terms used to describe productand order requirements, and criteria to apply to prioritisecustomer orders

• Basic operating principles of equipment and programsused to deliver the required birds to the correct locationswithin constraints of birds available and to generatesystem reports; an understanding of the main alarms andcorrective action required; an understanding oflocation/alignment requirements of sensors and relatedfeedback instruments located in the system hardware

• Limits and ranges to adjust for weight distribution• Related systems/activities and responsibilities for

interaction. These typically include related planning andscheduling; sales/customer service; bird receival, kill andevisceration; and packing



• Hazards, risks, controls and methods for monitoringprocesses within the system. This includes health andsafety, food safety, quality and environmental hazardsand risks

• Workplace system and approach to equipmentmaintenance

• Process improvement procedures and relatedconsultative arrangements. For example, this wouldinclude an understanding of options to minimise giveaway

• Troubleshooting procedures and problem solvingtechniques



Pre-requisite units

There are no pre-requisites for this unit.



• FDFZPRCI2A Operate a process control interface• FDFOPTSPC2A Apply principles of statistical process

control






• Personal protective clothing and equipment• Kill schedules, customer orders and related advice on

system requirements• Information on equipment capacity and operating

parameters• System equipment, software and related accessories and

services• Birds and packing hall• Communication and recording systems and procedures





FDFPODF3B Debone and fillet product (manually)Unit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

manually debone and fillet poultry.Unit Sector Poultry


1. Prepare thedeboning/filletingequipment and processfor operation

1.1 Washed and chilled carcasses or pieces are available tomeet production requirements

1.2 Equipment components are clean and set to meetoperating requirements



2. Monitor deboning/filletingprocess operation

2.1 Carcasses or pieces are delivered to the boning area2.2 Carcasses or pieces are inspected to confirm quality

specifications are met2.3 Bones are removed and fillets prepared to meet

specification2.4 Equipment is monitored to identify variation in operating





3. Shut down thedeboning/filleting process





FDFPODF3B Debone and fillet product (manually)


RANGE STATEMENT



• Legislative requirements are typically reflected inprocedures and specifications. Legislation relevant to thisindustry includes the Australian Food Standards Code,labelling, weights and measures legislation; andlegislation covering food safety, environmentalmanagement, occupational health and safety,anti-discrimination and equal opportunity


• Typical cuts may include Leonards cut, easy carve,maryland, boning out a turkey buff, and kiev

• Deboning/filleting equipment may include cones, boninglines (conveyor) or static lines




EVIDENCE GUIDE


Ability to: • Access workplace information to identify deboning/filletingprocess requirements

• Select, fit and use personal protective clothing and/orequipment. This include wearing of mesh gloves orsimilar protective clothing

• Confirm supply of necessary carcasses or pieces andrelated equipment such as tubs, crates and/or bins

• Conduct pre-start checks. This may involve inspectingknife and related equipment condition to identify anysigns of wear; selecting appropriate settings and/orrelated parameters; confirming that equipment is cleanand correctly configured for deboning/filleting processrequirements; sensors and controls are correctlypositioned; any scheduled maintenance has been carriedout, and that all safety guards are in place andoperational

• Debone and fillet product to meet specifications. Thisincludes demonstration of a range of cuts to requiredquality, time and yield

• Monitor boning and filleting process. This may includemonitoring:• product quality• clean removal of skin and bones as required• removal of fat, gristle, spots or bruised flesh• no bone fragments remain in product• yield• knife sharpness

• Monitor supply and flow of carcasses/pieces to theprocess




required• Complete workplace records as required• Maintain work area to meet housekeeping standards






Knowledge of: • Purpose of the deboning/filleting process. This includesan understanding of the skeletal structure of poultryproducts and the effect of this process on portion controland yield

• Quality characteristics to be achieved for the differenttypes of cuts required. This includes an understanding ofthe consequences of failing to remove bones and preparefillets to specification

• Quality requirements of carcasses/pieces suitable forprocessing and effect of variation on processperformance

• Basic operating principles of equipment used. Thisincludes an understanding of knife techniques and mayinclude an operational understanding of relatedequipment components such as conveyors

• Knife handling, sharpening, cleaning and storageprocedures

• The flow of the deboning/filleting process and the effect ofoutputs on downstream processes


• Contamination/food safety risks associated with thedeboning/filleting process and related control measures

• OHS hazards and controls. This includes safety related touse of knives



• Environmental issues and controls relevant to thedeboning and filleting process. This includes wastecollection and handling procedures related to the process





Pre-requisite units




• FDFZCSCS2A Clean and sanitize equipment








parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Deboning/filleting and related equipment and services• Carcasses/pieces to be filleted• Documentation and recording requirements and


required





FDFPODM2B Operate a dicing/stripping or mincingprocess

Unit Descriptor This is a Specialist unit. It covers the skills and knowledge required toset up, operate, adjust and shut down product dicing/stripping ormincing process.

Unit Sector Poultry


1. Prepare thedicing/stripping andmincing equipment andprocess for operation







2. Operate and monitor thedicing/stripping andmincing process




2.4 The process is monitored to confirm that diced/stripped orminced product meets specification




3. Shut down thedicing/stripping andmincing process





FDFPODM2B Operate a dicing/stripping or mincing process


RANGE STATEMENT





• Production equipment may include dicing/stripping ormincing equipment and tubs

• Materials typically include raw product free of bones orskin and may include additives/seasonings








EVIDENCE GUIDE


Ability to: • Access workplace information to identify dicing/strippingand mincing process requirements



equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured fordicing/stripping and mincing process requirements;sensors and controls are correctly positioned; anyscheduled maintenance has been carried out, and that allsafety guards are in place and operational

• Start, operate, monitor and adjust dicing/stripping processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include ensuring:• product flow rate• collection bins are monitored and removed as required• equipment performance

• Start, operate, monitor and adjust mincing processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include ensuring:• product flow rate• sequence of product and ingredient addition is to

production specifications• cutting/mixing times




required to take dicing/stripping and mincing process andrelated equipment off line in preparation for cleaningand/or maintenance within level of responsibility







Knowledge of: • Purpose and basic principles of the dicing/stripping andmincing process. This includes an understanding oftemperature generated by the process and effect onproduct

• Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents, status and purpose of guards, equipmentoperating capacities and applications and the purposeand location of sensors and related feedbackinstrumentation. It also includes knowledge of servicesrequired and action to take if services are not available

• The flow of the dicing/stripping and mincing process andthe effect of outputs on downstream processes

• Quality characteristics to be achieved by thedicing/stripping and mincing process

• Quality requirements of materials suitable for processingand effect of variation on process performance




• Contamination/food safety risks associated with thedicing/stripping and mincing process and related controlmeasures



the dicing/stripping and mincing process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage




• Environmental issues and controls relevant to thedicing/stripping and mincing process. This includeswaste/rework collection and handling procedures relatedto the process








Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Dicing/stripping and mincing process and related

equipment and services• Materials to be diced/stripped and minced• Sampling schedules and test procedures and equipment



required





FDFPOEP2B Operate an evisceration processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down the evisceration process todeliver the carcass ready for chilling.

Unit Sector Poultry


1. Prepare the eviscerationequipment and processfor operation

1.1 Carcasses are confirmed and available to meet operatingrequirements


1.3 Evisceration equipment is adjusted to meet safety andproduction requirements



2. Monitor eviscerationprocess operation




2.4 Viscera is removed to specification2.5 Out-of-specification product/process outcomes are




3. Shut down theevisceration process





FDFPOEP2B Operate an evisceration process


RANGE STATEMENT





• Stages and equipment in evisceration may include ventopeners/slitters, viscera/package removal, cropper, neckcracker, neck flap removal, foot removal, carcasswashing and conveyor systems


• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, vacuum, water and instrumentation air



• Where an operator is involved in backing up automatedevisceration processes but is not required to set up oradjust equipment, use FDFZPRMP1A Monitor processoperation




EVIDENCE GUIDE


Ability to: • Access workplace information to identify processrequirements



equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured forprocess requirements; spray jets are operating andpositioned correctly; waste product bins are positioned asrequired; any scheduled maintenance has been carriedout, and that all safety guards are in place andoperational.

• Start, operate, monitor and adjust evisceration processequipment to achieve required outcomes. This mayinclude conducting inspections as required to confirmviscera is removed to specification and adjustingequipment as required. Monitoring may include:• clean removal of parts such as neck flaps and feet as

required• vent/cloacae is opened and removed minimizing faecal

contamination• intestinal package is removed with lungs and liver

undamaged and visible• neck is broken and/or removed at required length• cavity is empty at final inspection point• carcass is washed and clean ready for chilling

• Monitor carcass quality. Monitoring may includeinspecting for:• faecal contamination/stains• broken bones• flesh damage/discolouration/red spotting/marks• size

• Monitor supply and flow of carcasses to and from theevisceration process

• Pace evisceration to complete timely processing of birdsfrom kill area




required to take evisceration process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility

• Demonstrate procedures to alter process for bird




size/type• Complete workplace records as required• Maintain work area to meet housekeeping standards






Knowledge of: • Purpose and basic principles of the evisceration process.This includes an understanding of the internal organs ofbirds, package removal requirements and consequencesof poor removal processes


• The effect of each stage of the evisceration process onthe quality of the end product

• Quality characteristics to be achieved by each stage ofthe evisceration process

• The effect of variation in carcass condition/age onevisceration process and outcomes



• Methods used to monitor the evisceration process. Thisrequires awareness of inspection or test points (controlpoints) in the process and the related procedures andrecording requirements

• Contamination/food safety risks associated with theevisceration process and related control measures


• OHS hazards and controls. This includes awareness ofthe use of protective clothing such as armguards andmesh gloves and the limitations of protective clothing andequipment relevant to the work process

• Requirements of different shutdowns as appropriate tothe evisceration process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage


• Adjustments required to take account of different birdsize/type


• Environmental issues and controls relevant to theevisceration process. This includes waste/reworkcollection and handling procedures related to the process








Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Evisceration process and related equipment and services• Carcasses• Documentation and recording requirements and


required





FDFPOGC2B Grade carcassUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

identify and grade carcass quality for further processing or packing.Unit Sector Poultry


1. Prepare the gradingprocess for operation

1.1 Washed and chilled carcasses are confirmed andavailable to meet operating requirements

2. Inspect and gradecarcasses

2.1 Carcasses are inspected and graded to workplace qualityspecifications

2.2 Out-of-specification product is identified, rectified andreported.



RANGE STATEMENT





• Grading related equipment typically includes conveyorsystems

• Grading could apply in any section where product ishandled


FDFPOGC2B Grade carcass


EVIDENCE GUIDE


Ability to: • Access workplace information to identify grading processrequirements


• Confirm supply of necessary materials and services• Inspect and grade birds. Inspection typically includes

checking:• neck trim• bruised/damaged birds• torn skin/muscle• presence of feathers• size• broken bones• discolouration• bile/faecal stains• moisture retention levels

• Monitor supply and flow of carcasses to and from thegrading process


• Locate emergency stop functions on equipment asrequired

• Follow isolation and lock out/tag out procedures asrequired to take grading process off-line in preparation forcleaning and/or maintenance, within level of responsibility





Knowledge of: • Purpose of the grading and weighing process. Thisincludes a detailed understanding of grading criteria andspecifications at each level and an understanding of theuses of product at each grade

• Common types of damage or out-of-specificationconditions and likely causes. This includes anunderstanding of damage likely to be caused by poorhandling of the carcass

• The flow of the grading process and the effect of outputson downstream processes

• Methods used to grade carcasses. This includes visualinspection and may include other methods. It includes anunderstanding of any further tests to support the gradingprocess

• Contamination/food safety risks associated with thegrading process and related control measures

• OHS hazards and controls• Isolation, lock out and tag out procedures and


and performance information• Environmental issues and controls relevant to the grading

process. This includes waste collection and handlingprocedures related to the process


Pre-requisite units







food safety, quality and environmental requirements• Production schedule/batch instructions• Specifications, control points and processing parameters• Weighing and grading process and related equipment

and services• Carcasses to be graded• Sampling schedules and test procedures and equipment



required




FDFPOHE2A Harvest edible offalUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

sort, harvest and clean edible offal.Unit Sector Poultry


1. Prepare the harvestingequipment and processfor operation

1.1 Product is transferred and available to meet productionrequirements

1.2 Equipment is checked and ready for use1.3 Pre-start checks are carried out as required by workplace

requirements

2. Harvest and sort edibleoffal

2.1 Edible offal is identified2.2 Offal is separated, sorted and collected to meet production

requirements2.3 Offal of unacceptable quality is identified and set aside2.4 The workplace meets housekeeping standards

3. Shut down the process 3.1 Edible offal and waste is collected and handled/removedas required

3.2 Process is shut down according to workplace procedures3.3 Maintenance requirements are identified and reported



FDFPOHE2A Harvest edible offal


RANGE STATEMENT





• Production equipment may include offal harvesting andcleaning equipment, bins, augers and conveyors

• The sorting process may be carried out manually and/oruse manual back-up of automated processes

• Edible offal may include giblets, livers, hearts, feet andnecks as required

• Inspection/monitoring is typically visual to confirmappearance of product





EVIDENCE GUIDE


Ability to: • Access workplace information to identify harvesting andcleaning process requirements



equipment condition such as conveyor belts to identifyany signs of wear; selecting appropriate settings,cancelling isolation or lockouts as required; confirmingthat work surfaces and related equipment are clean; andidentifying when blades need to be changed in the gibletmachine

• Start, operate, monitor and adjust harvesting andcleaning process equipment to achieve requiredoutcomes. This may include monitoring control points andconducting inspections as required to confirm processremains within specification

• Inspect quality of edible offal. This may include inspectingfor:• giblet colour and fat levels• presence of diseased or damaged organs• bile stain

• Identify and remove unacceptable product according toworkplace quality standards

• Monitor supply and flow of materials to and from theharvesting and cleaning process

• Sort, collect, recycle or dispose of inedible offal andwaste according to workplace procedure



required to take harvesting and cleaning process andrelated equipment off-line in preparation for cleaningand/or maintenance within level of responsibility







Knowledge of: • Purpose and basic principles of the harvesting andcleaning process. This requires an understanding of thestructure and internal organs of poultry to identify,separate and remove edible offal. It also requires anunderstanding of the contamination that can occur whenoffal is not correctly removed

• Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents, their purpose and operating capacities, andthe status and purpose of guards

• The flow of the harvesting process and the effect ofoutputs on downstream processes

• Quality standards for types of edible offal collected• Procedures for handling/recycling and/or disposing of

downgraded product• Typical equipment faults and related causes. This


• Methods used to monitor the harvesting process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection points (control points) in the harvesting andcleaning process and the related procedures andrecording requirements

• Contamination/food safety risks associated with theharvesting process and related control measures



• Requirements of different shutdowns as appropriate tothe harvesting and cleaning process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage



• Environmental issues and controls relevant to theharvesting process. This includes waste/rework collectionand handling procedures related to the process







Pre-requisite units




• FDFOPTCRM2A Conduct routine maintenance• FDFZCSCS2A Clean and sanitize equipment





parameters• Production schedule/batch instructions• Edible offal specifications, control points and processing

parameters• Quality parameters for grading/downgrading product• Offal harvesting, cleaning and washing equipment,

accessories and services• Offal to be harvested• Documentation and recording requirements and


required





FDFPOOIM2A Operate a marinade injecting processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down a marinade injection process.Unit Sector Poultry


1. Prepare the marinadeinjection equipment andprocess for operation

1.1 Carcasses and marinade are confirmed and available tomeet operating requirements


1.3 Machine components and related attachments areinspected and adjusted to meet operating requirements




2. Operate and monitor themarinade injectionprocess

2.1 Marinade is prepared and loaded to meet productionrequirements







3. Shut down the marinadeinjection process





FDFPOOIM2A Operate a marinade injecting process


RANGE STATEMENT





• Production equipment may include marinade mix tank,pump, and needle injection equipment








EVIDENCE GUIDE


Ability to: • Access workplace information to identify marinadeinjection process requirements


• Confirm supply of necessary marinade ingredients, wholebirds, materials and services

• Conduct pre-start checks. This may involve inspectingequipment condition to identify that needles are all inplace and not broken or bent; selecting appropriatesettings and/or related parameters; cancelling isolation orlockouts as required; confirming that equipment is cleanand correctly configured for marinade injection processrequirements; sensors and controls are correctlypositioned; any scheduled maintenance has been carriedout, and that all safety guards are in place andoperational.

• Start, operate, monitor and adjust marinade injectionprocess equipment to achieve required outcomes. Thismay include monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• pump operating parameters - speed/pressure (on

variable speed pumps)• conveyor speed• marinade level and temperature• needle position

• Monitor supply and flow of marinade and birds to andfrom the marinade injection process

• Take corrective action in response to out-of-specificationresults. This includes ability to demonstrate flushing ofneedles to clear blockages, within level of responsibility

• Demonstrate procedures to adjust process equipment forbird size/type



required to take marinade injection process and relatedequipment off-line in preparation for cleaning and/ormaintenance within level of responsibility







Knowledge of: • Purpose and basic principles of the marinade injectionprocess

• Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents including pumps and needle bed, status andpurpose of guards, equipment operating capacities andapplications, and the purpose and location of sensors andrelated feedback instrumentation

• The effect of marinade injection process on the quality ofend product

• The flow of the marinade injection process and the effectof outputs on downstream processes

• Quality characteristics to be achieved by the marinadeinjection process

• Quality requirements of marinade and bird carcasses andeffect of variation on process performance



• Methods used to monitor the marinade injection process.This may include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the marinadeinjection process and the related procedures andrecording requirements

• Contamination/food safety risks associated with themarinade injection process and related control measures.This includes knowledge of equipment checks requiredand traceability procedures to be followed where a brokenor damaged needle is identified




• Adjustment/changeover procedures to take account ofdifferent bird size/type



• Environmental issues and controls relevant to themarinade injection process. This includes waste/reworkcollection and handling procedures related to the process








Pre-requisite units




• FDFZPRCI2A Operate a process control interface• FDFOPTCRM2A Conduct routine maintenance• FDFZCIP2A Clean equipment in place• FDFZCSCS2A Clean and sanitize equipment





parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Marinade preparation and injection and conveying

process and related equipment and services• Birds to be processed and marinade premix• Documentation and recording requirements and


required





FDFPOOWC2A Operate a washing and chilling processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down spin and/or air chilling equipmentused to wash and chill carcasses.

Unit Sector Poultry


1. Prepare the chillingequipment and processfor operation

1.1 Carcasses are confirmed and available to meet operatingrequirements





2. Operate and monitor thechilling process








3. Shut down the chillingprocess





FDFPOOWC2A Operate a washing and chilling process


RANGE STATEMENT





• Production equipment may include washers, spin or airchillers, pumps and dosing equipment and conveyorsystems




• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower, water, refrigerant and instrumentation air




EVIDENCE GUIDE


Ability to: • Access workplace information to identify chilling processrequirements



equipment condition to identify any signs of wear;selecting appropriate settings and/or related parameters;cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured forchilling process requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational. Inspections may include confirming:• water tank levels• operation of ice conveyor• operation of pumps and chlorine dosing equipment

• Start, operate, monitor and adjust chilling processequipment to achieve required outcomes. This mayinclude monitoring control points and conductinginspections as required to confirm process remains withinspecification. Monitoring may include:• water overflow rates• chlorine level• chiller/water temperature• air temperature (air chillers)• washer agitation• carcass immersion time• deep muscle temperature• and ensuring carcasses are shackled securely as they

come out of the spin chiller• Monitor supply and flow of product and services to and

from the chilling process• Take corrective action in response to out-of-specification



required to take chilling process and related equipmentoff-line in preparation for cleaning and/or maintenancewithin level of responsibility

• Demonstrate changeover procedures to adjust for birdsize






Knowledge of: • Purpose and basic principles of the chilling process. Thisincludes an understanding of the purpose of both washingand chilling as it affects bacterial load


• The effect of each stage on the quality of end product.This includes an understanding of the relationshipbetween immersion time, water temperature and agitationon the amount of water absorbed by the carcass and onwashing efficiency

• The flow of the chilling process and the effect of outputson downstream processes

• Quality characteristics to be achieved by the chillingprocess

• Quality requirements of carcasses and materials andeffect of variation on chilling process performance

• Operating requirements and parameters and correctiveaction required where operation is outside specifiedoperating parameters. This may include an understandingof specifications for temperature range of washers andchillers


• Methods used to monitor the chilling process. This mayinclude inspecting, measuring and testing as required bythe process. It requires awareness of inspection or testpoints (control points) in the chilling process and therelated procedures and recording requirements. Thisincludes procedures for measuring deep muscletemperature

• Changeover procedures• Contamination/food safety risks associated with the

chilling process and related control measures• Common causes of variation and corrective action

required• OHS hazards and controls. This includes awareness of


• Requirements of different shutdowns as appropriate tothe chilling process and workplace productionrequirements. This includes emergency and routineshutdowns and procedures to follow in the event of apower outage






• Environmental issues and controls relevant to the chillingprocess. This includes waste/rework collection andhandling procedures related to the process



• Sampling and testing associated with chilling processmonitoring and control



Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Washing and chilling and conveying process, related

equipment and services• Carcasses to be washed and chilled• Sampling schedules and test procedures and equipment



required





FDFPOPS2A Operate a portion sawUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate and adjust a portion saw.Unit Sector Poultry


1. Prepare portion saw foroperation

1.1 Safety guards and covers are in place1.2 Pre-start checks are carried out as required by workplace

requirements

2. Operate the portion saw toachieve required outcome

2.1 Portions to be cut are positioned2.2 The portion is passed over the blade and cut to meet

specifications2.3 Equipment is monitored to identify variation in operating



2.5 Quality and accuracy of cuts is monitored to confirm thatspecifications are met.

2.6 Equipment is inspected and cleaned according toworkplace procedures



RANGE STATEMENT





• Equipment includes a portion saw that is fixed in position,and materials handling equipment as required


FDFPOPS2A Operate a portion saw


EVIDENCE GUIDE


Ability to: • Access workplace information to identify portionrequirements

• Select, fit and use personal protective clothing and/orequipment. This includes use of mesh gloves or similarprotective clothing

• Confirm supply of necessary poultry pieces. This includesinspecting and removing pieces of unacceptable quality

• Conduct pre-start checks. This may involve inspectingcondition of the portion saw to identify blade sharpnessand other signs of wear; cancelling isolation or lockoutsas required; and confirming that equipment is clean, allsafety guards are in place and operational and thatlighting, guarding and signage around the saw are inposition

• Collect portions to be cut• Position portions to allow the blade to pass cleanly

through• Achieve cut accuracy to meet specifications and

workplace standards with minimal waste• Identify faulty equipment operation and/or blunt blades

and take corrective action• Respond to and/or report equipment failure within level of


required to take the portion saw and related equipmentoff-line in preparation for cleaning and/or maintenancewithin level of responsibility

• Complete workplace records as required• Inspect and clean portion saw and report maintenance

issues as required• Maintain work area to meet housekeeping standards


• Conduct routine maintenance such as blade replacement




Knowledge of: • Quality specifications and characteristics required ofportioned product

• Portion saw operating procedures. This includes correctpositioning of guards, lighting and safe work practiceswhen working with the saw


• Contamination/food safety risks associated with theautomated cutting process and related control measures.This includes hygiene and sanitation requirements whenhandling product

• Grading/downgrading specifications for portioned product• The effect of outputs on downstream processes• Typical equipment faults and related causes. This




• Procedures for cleaning and for reporting maintenancerequirements

• Waste handling requirements and procedures




Pre-requisite units




• FDFOPTCRM2A Conduct routine maintenance• FDFZCSCS2A Clean and sanitize equipment






• Personal protective clothing and equipment. This mustinclude a mesh glove

• Work procedures including advice on safe work practices,food safety, quality and environmental requirements


• Production schedule/batch instructions• Specifications, control points and processing parameters• Portion saw and related equipment and services• Carcasses/pieces to be cut into portions• Documentation and recording requirements and


required





FDFPORH2A Operate the bird receival and hangingprocess

Unit Descriptor This is a Specialist unit. It covers the skills and knowledge required toreceive and hang live poultry.

Unit Sector Poultry


1. Prepare the receiving andhanging equipment andprocess for operation

1.1 Live birds are confirmed and available to meet operatingrequirements

1.2 Equipment is adjusted to meet safety and operatingrequirements


2. Receive and hang birds 2.1 Birds are inspected and confirmed against loaddocumentation

2.2 Conveyors and related equipment are operated to meetunloading requirements


2.4 Bird condition is inspected and unacceptable birds areremoved

2.5 Birds are hung according to workplace procedures2.6 The workplace meets housekeeping standards2.7 Workplace records are maintained according to workplace


3. Shut down the receivingand hanging process

3.1 The receival conveyors and related equipment are shutdown according to workplace procedures



FDFPORH2A Operate the bird receival and hanging process


RANGE STATEMENT


Range description • Work is carried out according to company policies andprocedures, RSPCA standards, regulatory and licensingrequirements, legislative requirements; and industrialawards and agreements


• Workplace information may include Standard OperatingProcedures (SOPs), specifications, deliverydocumentation, production schedules, manufacturers'advice, standard forms and reports

• Production equipment may include bird holding/storagefacilities, unloading equipment, conveyors, dust extractionand bird shackling systems

• Birds may be received in multi-layered modules or crates• Operation of equipment and processes may require the




• Services may need to be confirmed. These depend onthe nature of the process. Typical examples includepower and water




EVIDENCE GUIDE


Ability to: • Access workplace information to identify receival andhanging process requirements


• Confirm supply of necessary birds and services• Conduct pre-start checks. This may involve inspecting

condition of conveyors and shackles to identify any signsof wear; selecting appropriate settings; cancellingisolation or lockouts as required; confirming thatequipment is clean and correctly configured for receival,and hanging process requirement. It also includes checksto confirm and maintain the receival environment. Thismay include:• checking airflow in receivals area• checking operation of related equipment such as dust

extractors• checking humidity gauges/ambient temperature• confirming that birds are under minimal stress

• Unload birds and confirm condition. This includesremoving any dead or poorly conditioned birds

• Retrieve escaped birds, causing minimal stress• Hang birds according to workplace procedure• Demonstrate procedures for adjusting equipment for

different bird sizes/types as appropriate• Sequence receival and hanging activities to minimise time

between receival and processing• Respond to and/or report equipment failure within level of




• Use process control systems• Check and confirm weighbridge documentation against

order• Conduct routine maintenance• Clean and sanitize equipment




Knowledge of: • Basic principles of bird handling. This includes anunderstanding of humane treatment of birds, conditionsthat stress birds and environmental design features tominimise stress including airflow, humidity andtemperature controls

• RSPCA standards relating to bird handling• Basic operating principles of equipment. This may include

an operational understanding of the conveyor system andrelated load shifting equipment and other equipment usedincluding dust extractors. It may also include the purposeand location of sensors and related feedbackinstrumentation

• Acceptable time from bird receival to bird processing andconsequences of delays in processing on product quality

• The flow of the receival and hanging process on furtherprocessing or packing stages to produce a final product

• Changeover requirements to adjust for bird size/type• Operating requirements and parameters and corrective



• Methods used to monitor the receival and hangingprocess. This may include monitoring that the receivalprocess is paced to deliver birds to processing and/orpacking areas without delay, bird condition is acceptable,the receival environment is appropriate and birds areshackled correctly

• Consequences of poor receival and hanging on productquality


the receival, and hanging process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage



• Environmental issues and controls relevant to thereceival, and hanging process. This includes proceduresfor disposing of dead or unfit birds



• Receival documentation and related load identificationprocedures






Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Receival, and hanging process and related equipment

and services• Birds• Documentation and recording requirements and


required





FDFPOSK2B Operate a stunning, killing and defeatheringprocess

Unit Descriptor This is a Specialist unit. It covers the skills and knowledge required toset up, operate, adjust and shut down a process to stun, kill anddefeather birds.

Unit Sector Poultry


1. Prepare the stun, kill anddefeather equipment andprocess for operation

1.1 Birds are confirmed and available to meet operatingrequirements


1.3 Machine components and related attachments are fittedand adjusted to meet safety and operating requirements

1.4 Operating parameters are entered as required to meetbird size and type



2. Monitor each stage of thestun, kill and defeatherprocess




2.4 The process is monitored to confirm that birds arestunned, killed and bled to specification

2.5 Feathers and heads are removed to specification2.6 Out-of-specification product/process outcomes are




3. Shut down the stun, killand defeather process





FDFPOSK2B Operate a stunning, killing and defeathering process


RANGE STATEMENT





• Production equipment may include stunner, knives,bleeding tunnels, scalding tank, plucking equipment, headand trachea puller and feather collection systems



• Operators carry out changeovers within workplacearrangements and the relevant changeover proceduresshould be used to customise the details of this unit.Where more detailed changeovers are carried out, alsorefer to FDFOPTCRM2 A Conduct routine maintenance


• Where an operator is involved in backing up automatedstunning, killing and defeathering processes but is notrequired to set up or adjust equipment, useFDFZPRMP1A Monitor process operation




EVIDENCE GUIDE


Ability to: • Access workplace information to identify stun, kill anddefeather process requirements



equipment condition to identify any signs of wear;selecting appropriate settings according to bird size/type;cancelling isolation or lockouts as required; confirmingthat equipment is clean and correctly configured forprocess requirements; sensors and controls are correctlypositioned; any scheduled maintenance has been carriedout, and that all safety guards are in place andoperational. Inspections may include confirming:• comfort bar and guides are correctly positioned• blades are sharp, rotating and correctly positioned for

bird size• scald tank temperatures are within range• condition of fingers on defeatherer/plucker• defeatherer/plucker and head removal equipment are

adjusted for bird size/type• Start, operate, monitor and adjust the stun, kill and

defeather process equipment to achieve requiredoutcomes. This may include monitoring control points andconducting inspections as required to confirm processremains within specification. Monitoring may include:• bleeding time• scald water temperature and immersion time• line speed• feather removal• angle and height head removal

• Monitor supply and flow of materials to and from the stun,kill and defeather process to the evisceration process










Knowledge of: • Purpose and basic principles of each part of the stun, killand defeather process


• The effect of each stage on the quality of end product.This includes an understanding of the relationshipbetween the bleeding stage and final product quality andbetween scald temperature/immersion time on thedefeathering stage

• The stun, kill and defeather process and the effect ofoutputs on downstream processes

• Quality characteristics to be achieved by the stun, kill anddefeather process



• Methods used to monitor the stun, kill and defeatherprocess. This requires awareness of inspection or testpoints (control points) in the process and the relatedprocedures and recording requirements

• Contamination/food safety risks associated with the stun,kill and defeather process and related control measures



the stun, kill and defeather process and workplaceproduction requirements. This includes emergency androutine shutdowns and procedures to follow in the eventof a power outage



• Environmental issues and controls relevant to the stun,kill and defeather process. This may include anunderstanding of systems in place to collect, treat anddispose of waste and biproducts such as blood, water,feathers and bird parts









Pre-requisite units









parameters• Production schedule• Specifications, control points and processing parameters• Stunning, killing and defeathering equipment and related

conveying process and services• Birds to be processed• Documentation and recording requirements and


required





FDFPIOWP4A Optimise a work processUnit Descriptor This unit covers the skills and knowledge required to assess,

investigate and make recommendations to optimise the performance ofa work process, system or area.

Prerequisite Unit(s) FDFOPTPIP3A Participate in improvement processesUnit Sector Process Improvement


1. Identify work processscope

1.1 The scope and flow of the work process is identified1.2 Work process information is identified and collected

2. Assess work processperformance

2.1 Work process performance is assessed against plan andbenchmark information

2.2 Variations in work process performance are identified andinvestigated

2.3 Opportunities for improvement are identified

3. Develop a plan to optimiseprocess performance

3.1 Recommendations for improvements are developed andreported in the appropriate format

3.2 An implementation plan is developed and presented in theappropriate format

4. Implement, monitor andevaluate processimprovement

4.1 Workplace documentation is reviewed to reflect processimprovement

4.2 Changes to roles and responsibilities of workplacepersonnel involved in implementing the optimisation planare identified and communicated

4.3 Resources to support implementation are identified,negotiated and secured

4.4 Process changes are implemented and monitored4.5 Continuous improvement procedures are applied to

evaluate and refine process optimisation




RANGE STATEMENT


Range description • Changes introduced through process optimisation areconsistent with company policies and procedures,regulatory and licensing requirements, legislativerequirements, and industrial awards and agreements andtakes account of OHS and environmental impact ofscheduling arrangements

• Work process information includes but is not limited tohistorical data on performance of process and equipment,costs, raw materials/ingredient grades and suppliers,packaging components/consumables type and suppliers,energy efficiency, labour efficiency, resource/servicecosts, throughput times, and changeover times

• Options for process optimisation may include but are notlimited to removing unnecessary process steps,improving communication, changing rawmaterials/ingredients and/or packagingcomponents/consumables grades/types, changing workpractices and/or equipment, and changing labourallocation/skill composition

• Process optimisation typically involves facilitation ofconsultation and performance improvement processes




EVIDENCE GUIDE


Ability to: • Define the purpose and scope of the work process anddevelop a process map/workflow diagram. Processmaps/workflow diagrams should include information onthe steps in the process under examination and theinteraction of the process with related customers andsuppliers

• Identify steps in the process or conditions that result inworkflow blockages or sub-optimal performance. This istypically undertaken in consultation with processoperators

• Use workplace data to develop/confirm processperformance information. This includes but is not limitedto historical information on process and equipmentperformance. Where processes are seasonal, it shouldinclude reference to similar points in the cycle forcomparative purposes

• Identify criteria against which to assess processperformance. This includes but is not limited toperformance plans/targets, equipment operating capacity,process capability and relevant benchmark information asappropriate/available

• Assess process performance information against agreedcriteria

• Identify sub-optimal performance events and/or patternsand investigate cause. This may involve facilitation of aninvestigation team

• Identify opportunities to remove or minimise causes ofsub-optimal process performance

• Evaluate opportunities and assess related costs/benefitsfor each option

• Recommend preferred option/s and reportrecommendations in the required workplace format

• Develop an implementation plan. This includes identifyingresource requirements, personnel affected andappropriate communication strategy, revised/newworkplace documentation and evaluation/review process

• Negotiate and secure resources to supportimplementation

• Communicate proposals/implementation plan, invitefeedback and take feedback into account

• Follow continuous process procedures and monitor andreview changes against improvement criteria


• Trial changes prior to full implementation• Arrange training/development opportunities




Knowledge of: • Process/workflow mapping purpose and techniques• Characteristics of the work process. This includes an

understanding of typical factors that affect processperformance Factors typically include but are not limitedto:• fluctuations in demand/throughput• quality of raw material/ingredient inputs• human resources availability/competencies• equipment configuration, capacity and performance• process capability• changeover times• cost of services

• Criteria against which to assess performance. This mayinclude Key Performance Indicators (KPIs), productionplans/schedules, budgets and relevant benchmarkinformation

• Technical knowledge to identify and assess currentperformance and identify improvement opportunities andproposals

• Process improvement tools and techniques• Communication skills to facilitate consultation processes

and report, record and present information in the requiredformats. This includes an understanding of relatedworkplace documentation and systems

• Relevant personnel and departments to beconsulted/notified of optimisation implementation plan



Pre-requisite units


• FDFOPTPIP3A Participate in improvement processes



• FDFOPTTG3A Lead work teams and groups• BSBCMN405A Analyse and present research information



• Information storage and retrieval systems• Access to relevant workplace records and benchmarking

information• Opportunities to interact with others using typical

workplace communication processes• Workplace systems and procedures for consultation,

feedback and continuous improvement




FDFRBAB3A Produce artisan breadsUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the skills and knowledge required to plan and produce a range ofartisan breads. This includes flat breads, national and regional breads.

Prerequisite Unit(s) FDFRBSM2B Scale and mould dough for intermediate proofFDFRBPY2B Produce yeast-raised productsFDFRBPD2B Produce bread doughFDFRBFM2B Conduct final mould and final proofFDFRBBB2B Bake bread

Unit Sector Retail Baking


1. Plan and sequencepreparation of artisanbreads

1.1 Recipe is selected to meet product/customer requirements1.2 Preparation and production stages are planned

2. Produce bread doughs fora range of artisan breads

2.1 Ingredients are selected to suit recipe specifications2.2 Dough is prepared meet product requirements

3. Prepare and bake a rangeof artisan breads

3.1 Dough is prepared for baking according to productrequirements

3.2 Product is baked to meet quality requirements3.3 Final product is presented to meet food safety and

customer requirements

4. Cost and price finalproduct

4.1 Product ingredients are costed4.2 Production costs are estimated4.3 Product is priced within business pricing policy4.4 Actual costs are measured against estimated costs


FDFRBAB3A Produce artisan breads


RANGE STATEMENT




• Workplace information can include verbal or writtenoperating procedures, specifications, productionschedules and recipe instructions

• National and regional breads include festive and religiousbreads

• Dough preparation depends on product/bread type.Typical steps include scaling/rounding, intermediateproof, moulding/shaping, final proof, topping and baking

• Enriched dough products include brioche and cholla• Note that this unit specifies minimum ingredient and

product preparation requirements. Where these havebeen covered in earlier units of competency, theseaspects of the unit do not need to be reassessed




EVIDENCE GUIDE


Ability to: • Given product description and/or customer request, selectappropriate recipe/formulation to meet product/customerrequirements

• Price ingredients for use in product• Estimate cost of production• Select ingredients to meet recipe requirements• Produce bread dough to meet recipe requirements. This

must include but is not limited to producing:• dough-based flat bread dough• batter-based flat bread dough• unleavened or chemically leavened flat bread dough• chemical sour dough• natural sour dough• an extended fermentation period dough• an enriched dough

• Prepare cultures/starters for use in sours from scratch,using a natural sour dough and using a chemical starter

• Prepare dough for baking according to requirements ofbread type. This includes moulding/shaping, such asnovelty shapes and plaited products

• Bake bread products• Finish and present bread product to meet product and

customer requirements. This includes applying toppingsas required

• Clean equipment and utensils to meet hygiene standards• Maintain workplace records as required• Maintain work area to meet housekeeping standards• Measure actual production costs against estimate and

account for any variation




Knowledge of: • Typical formulations for bread types• Principles and processes involved for extended

fermentation doughs• Fermentation process in chemical and natural sour

doughs as this affects dough preparation, baking and finalproduct characteristics, and related food safety issues

• Preparation stages and requirements for nominatedbread types. This includes but is not limited to aknowledge of:• starter preparation• dough scaling and rounding methods including

sheeting, hand and mechanical scaling and rounding• intermediate proof methods including ambient

temperature and normal proofing• moulding including novelty shapes and plaited product

preparation• loading product into ovens. This includes stretching flat

bread doughs such as Turkish bread on the oven floor• baking parameters for different bread types• the effect of ingredients on shelf-life and food safety

• Optimum storage conditions and shelf-life for ingredientsand related sequencing requirements

• Optimum storage conditions for the finished product priorto sale

• Ingredient suppliers and pricing information• Methods of estimating fixed and variable costs, and profit

margin to determine sale price range• Basic awareness of trade practice issues when pricing

products• Business policy and parameters in pricing products


Pre-requisite units

The pre-requisite units for this competency standard are:

• FDFRBBB2B Bake bread• FDFRBFM2B Conduct final mould and final proof• FDFRBPD2B Produce bread dough• FDFRBPY2B Produce yeast-raised products• FDFRBSM2B Scale and mould dough for intermediate

proof








• Work procedures including advice on relevant productrequirements, safe work practices, food safety, qualityand environmental requirements

• Recipes and customer specifications• Production equipment appropriate to product type• Materials/ingredients to meet recipe requirements• Ingredient pricing information• Personal protective clothing, equipment and material

safety data sheets as required• Cleaning procedures, materials and equipment as

required





FDFRBBB2B Bake breadUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the principles, equipment and procedures used to bake bread in anin-store bakery or retail baking environment.



1. Prepare to bake dough 1.1 Baking parameters are selected as required to meetsafety and baking requirements

1.2 Dough pieces are loaded into the oven1.3 Ingredients are confirmed and available to meet finishing

requirements

2. Bake bread 2.1 Ovens are operated to meet required output2.2 Baked product meets food safety and quality requirements2.3 Unacceptable baked product is identified, rectified and/or

reported2.4 Housekeeping standards are maintained in the workplace

RANGE STATEMENT





• Ovens may be loaded manually, or by placing trays orusing slips and belts according to workplace equipment


FDFRBBB2B Bake bread


EVIDENCE GUIDE


Ability to: • Access workplace information to identify recipe/bakingrequirements

• Select appropriate oven settings and start up the oven.This includes setting time and temperature controls

• Load dough pieces• Schedule loads according to volume and temperature

requirements to achieve time and energy efficiencies• Monitor baking process. This includes monitoring:

• steam injection (as required)• crust colour• sheen• uniformity of shape• size (oven spring)

• Take corrective action as required to maintain quality ofproduct

• Maintain workplace records as required• Maintain work area to meet housekeeping standards

Knowledge of: • Changes that occur to the product during baking• How dough characteristics such as shape/size and skin

formation affect the final product• The effect of variables such as time, temperature and

humidity on baking• The effect of yeast activity on the final product• Quality characteristics of final product including:

• volume• grain• texture• crumb colour• crust formation and colour

• Settings, operating requirements and safety features ofequipment used

• Causes of variation and corrective action required• Control points and related monitoring requirements• OHS hazards and controls• Waste handling and cleaning requirements


Pre-requisite units









• Personal protective clothing and equipment• Work procedures including advice on relevant product

requirements, safe work practices, food safety, qualityand environmental requirements

• Recipe instructions• Specifications, control points and processing settings• Baking equipment• Bread dough that has undergone final moulding and proof• Personal protective clothing, equipment and material


required





FDFRBBC2B Bake sponges, cakes and cookiesUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the principles, equipment and procedures used to bake sponges, cakesand cookies in an in-store bakery or retail baking environment.



1. Prepare to bake product 1.1 Baking parameters are selected as required to meetsafety and baking requirements

1.2 Batter is available and tinned or deposited ready forbaking

2. Bake products 2.1 Ovens are operated to meet required output2.2 Baked product meets food safety and quality requirements2.3 Unacceptable baked product is identified, rectified and/or


RANGE STATEMENT





• Equipment may include topping equipment, oven loadingequipment, ovens and cooling racks


FDFRBBC2B Bake sponges, cakes and cookies


EVIDENCE GUIDE


Ability to: • Access workplace information to identify bakingrequirements

• Confirm product is correctly deposited and ready forbaking


• Load product. This can include positioning product ontrays, slips or belts with correct spacing

• Monitor baking process. This includes monitoring:• colour• appearance/shape• time

• Remove baked products from oven and cool, turn out andpresent finished product. This can include placing oncooling racks

• Take corrective action as required to maintain quality ofproduct

• Maintain workplace records as required• Maintain work area to meet housekeeping standards


• Finish products• Decorate cakes and cookies

Knowledge of: • Basic principles of cake, sponge and cookie production• Effect of ingredients on baking process and final product• Cooling methods• Required characteristics of final product• Process requirements. This may include:

• baking times and temperatures• oven settings• settings, operating requirements and safety features of

equipment used• Product presentation and storage requirements. This can

include an understanding of refrigeration and shelf-life• Product cooling and handling methods to preserve

product quality• Control points and related monitoring requirements• Causes of variation and corrective action required• Control points and related monitoring requirements• OHS hazards and controls• Waste handling and cleaning requirements


• Finishing baked products• Decorating cakes and cookies





Pre-requisite units








• Baking instructions• Specifications, control points and processing settings• Baking equipment (this includes depositing equipment,

tins and trays as required )• Sponge, cake and/or cookie batter• Personal protective clothing, equipment and material


required





FDFRBBP2B Bake pastry productsUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the principles, equipment and procedures used to bake pastry in anin-store bakery or retail baking environment.



1. Prepare to bake pastryproducts

1.1 Baking parameters are selected as required to meetsafety and baking requirements

1.2 Product is prepared, finished and arranged to meet qualityand product requirements

2. Bake products 2.1 Ovens are operated to meet required output2.2 Baked product meets food safety and quality requirements2.3 Unacceptable baked product is identified, rectified and/or


RANGE STATEMENT





• Product may be prepared fresh or frozen• Equipment may include topping equipment, oven loading

equipment, ovens and cooling racks


FDFRBBP2B Bake pastry products


EVIDENCE GUIDE


Ability to: • Access workplace information to identify bakingrequirements

• Prepare product for baking. This may include thawingfrozen product and allowing the requireddevelopment/conditioning of product prior to baking. Itcan also include applying finishings or glazes


• Load product. This can include positioning product ontrays, slips or belts with correct spacing

• Select required oven settings. This may include settingtime, temperature and steam controls

• Monitor baking process. This includes monitoring:• colour• appearance/shape• seals that they show no signs of boil out

• Remove baked products from oven and cool to meetrequired temperature

• Present, package and/or store as required• Apply washes and/or glazes before or after baking as

required• Take corrective action as required to maintain quality of

product• Maintain workplace records as required• Maintain work area to meet housekeeping standards

Knowledge of: • Changes that occur to the product during baking• How pastry product characteristics affect the final product• Time required for conditioning products• The effect of variables such as temperature of fillings,

time, temperature and humidity during the baking process• Quality characteristics of the final product• Presentation and/or storage requirements for baked

product. This can include an understanding ofrefrigeration, freezing and shelf-life


• Causes of variation and corrective action required• Control points and related monitoring requirements• OHS hazards and controls• Waste handling and cleaning requirements





Pre-requisite units








• Recipe instructions• Specifications, control points and processing settings• Baking equipment• Pastry products• Personal protective clothing, equipment and material


required





FDFRBCP2B Produce choux pastryUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the principles, equipment and procedures used to produce choux pastryin an in-store bakery or retail baking environment.




1.1 Ingredients are confirmed and available to meet productrequirements

1.2 Ingredients are weighed and/or measured to meet reciperequirements

1.3 Equipment is checked to confirm readiness for use1.4 Ingredients are loaded into the mixer to meet recipe

requirements1.5 Mixing equipment is set and operated to meet recipe

requirements1.6 Mix meets specifications

2. Shape or form product 2.1 Pastry is piped, dropped or deposited to meet productrequirements

2.2 Choux pastry product meets food safety and qualityrequirements

2.3 Unacceptable dough is identified, rectified and/or reported

3. Clean equipment 3.1 Equipment is cleaned to meet production and hygienerequirements

3.2 Waste is disposed of according to workplace procedure3.3 Housekeeping standards are maintained in the workplace


FDFRBCP2B Produce choux pastry


RANGE STATEMENT





• Ingredients include but are not limited to flour, eggs,shortening, sugar, salt, leavening agent and water

• Equipment may include mixers, sieves, lifting equipment,sheeting equipment, piping equipment and ovenequipment

• Shortening may be added to the mixer or worked into thedough manually




EVIDENCE GUIDE


Ability to: • Access workplace information to identify reciperequirements

• Confirm condition, type, quality and quantity ofingredients. This includes selecting shortening type tomeet recipe requirements

• Weigh, scale or meter ingredients as required• Confirm equipment status and condition• Cook shortening, flour and water until starch is cooked• Cool roux-type mixture to required temperature• Set mixing equipment to meet production requirements.

This can include:• selecting and fitting appropriate attachments• setting mixer times and speeds

• Transfer ingredients to the mixer in the requiredsequence

• Add egg to meet recipe requirements• Monitor the appearance and consistency of mix and

ensure that all ingredients are added• Pipe or drop pastry to meet product requirements• Take corrective action as required so that mixture meets

quality standards• Clean equipment and utensils to meet hygiene standards• Maintain workplace records as required• Maintain work area to meet housekeeping standards


• Finish products




Knowledge of: • Basic principles of making choux pastry• Ingredient characteristics and purpose in pastry. This

includes an understanding of shortening types, flourtypes, components and effect on pastry

• Methods used to confirm accuracy of measuringequipment used

• Process requirements. This may include:• mixing times and speeds• appearance and consistency to be met• piping or dropping

• Required characteristics of choux pastry, uses andrelated processing methods

• Significance of factors such as time and temperatureduring mixing and the rate and sequence of ingredientaddition on the final product


• Product presentation and storage requirements. This caninclude an understanding of refrigeration, freezing andshelf-life of final product

• Causes of variation and corrective action required• Settings, operational requirements and safety features of

mixing equipment• Control points and related monitoring requirements• OHS hazards and controls• Waste handling and cleaning and procedures


• Preparing and applying decorations to finish products


Pre-requisite units









• Work procedures including advice on relevant chouxpastry preparation requirements, safe work practices,food safety, quality and environmental requirements

• Recipe instructions• Product specifications and related inspection/control

points• Mixing and piping equipment as required by choux

product type• Materials/ingredients• Personal protective clothing, equipment and material


required





FDFRBDC2B Decorate cakes and cookiesUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the skills and knowledge required to prepare and apply decoratingmaterials such as fondants and ganache and use a range of typicaldecorating techniques.



1. Prepare to decorate cakesand cookies

1.1 Ingredients are confirmed and available to meet finishingrequirements

1.2 Equipment is checked to confirm readiness for use1.3 Decorations and decorating materials are available to

meet product decorating requirements

2. Decorate products to meetquality and customerrequirements

2.1 Decorating materials are applied to meet presentationrequirements

2.2 Finished product meets presentation requirements2.3 Unacceptable product is identified, rectified or reported2.4 Products are assembled to meet customer and quality

requirements2.5 Housekeeping standards are maintained in the workplace


FDFRBDC2B Decorate cakes and cookies


RANGE STATEMENT





• Decorating materials may include but are not limited tocake ornaments and decorations; fresh, mock or buttercream; fudge and other icing sugar; fondant; chocolate;glazes; fruit; custard; mousses and similar fillings andcoverings. These may be prepared from scratch orpurchased for use

• Typical equipment includes piping bags and nozzles,mixing bowls and application utensils such as spatulasand palette knives

• Typical decorating techniques include flooding, icing ormasking cakes; finishing cake sides; piping to producedecorative finishes and write simple messages; andplacement or arrangement of ornaments and decorations.It may also include applying the final layer of materials tofinish a product

• Decorating is done within design specification parameters




EVIDENCE GUIDE


Ability to: • Confirm customer requirements• Select and/or follow appropriate decorating instructions• Confirm that the required type and quantity of cake

ornaments, decorations and decorating materials and/oringredients are available

• Confirm that required equipment is clean and ready foruse

• Mix or prepare decorating materials as required• Select and mount cakes on appropriate cake bases• Demonstrate a range of decorating techniques to suit the

product. At a minimum, decorating techniques willinclude:• flooding, icing or masking cakes• writing simple messages• using more than one decorating material to achieve the

required finish• applying decorating materials to cover cakes in a

timely manner to achieve an even, clean finish asrequired by product and customer requirements

• Identify and take corrective action to ensure that finishedproduct meets quality standards

• Clean equipment and utensils to meet hygiene standards• Maintain workplace records as required• Maintain work area to meet housekeeping standards


• Temper chocolate




Knowledge of: • Methods used to prepare a range of decorating materials.This includes preparation of ganache and fondants

• Characteristics, role and storage requirements ofmaterials used

• Required characteristics of prepared decorating materials• Methods used to prepare powdered and liquid

colours/flavours• Methods used to confirm accuracy of measuring

equipment used• Board types, sizes and appropriate medium to secure

cake to cake base• Acceptable standards for equipment/utensils used. This

includes an understanding of cleaning requirements, andsigns of wear or unacceptable damage. Where measuringequipment is used, it may also include procedures suchas taring of scales

• Decorating techniques such as flooding, icing or masking,piping of simple messages and decorative finishes, andplacement of ornaments and decorations

• The effect of variables such as the temperature ofdecorating materials and application time on the finishedproduct

• Product quality, presentation and storage requirements.This can include an understanding of refrigeration,freezing and shelf-life

• Inspections/control points used to confirm that productmeets quality requirements and related monitoringrequirements

• Causes of variation and corrective action required• OHS hazards and controls• Waste handling and cleaning requirements and

procedures


• Chocolate preparation and tempering


Pre-requisite units









• Work procedures including advice on relevant productdecoration requirements, safe work practices, food safety,quality and environmental requirements

• Recipe/decorating instructions• Product specifications and related inspection/control

points• Product to be decorated and related decorating materials

and equipment• Personal protective clothing, equipment and material


required





FDFRBDPB3A Diagnose and respond to product andprocess faults (bread)

Unit Descriptor This is a Specialist unit. It builds on the problem solving skillsdeveloped in operational units and provides technical competencies tosupport problem solving relating to bread production.



1. Identify causes ofunacceptable productquality

1.1 Unacceptable products are analysed to determine cause1.2 Process parameters and reactions which occur during

processing are monitored

2. Take corrective actionaccording to workplaceprocedures

2.1 Corrective action is taken to remove unacceptable productand prevent recurrence of the problem according toworkplace procedures

2.2 Corrective action is recorded according to workplaceprocedures and food safety program

RANGE STATEMENT




• Raw materials include those used to manufacture breadproducts

• Causes of unacceptable quality may relate to rawmaterials, processing and/or storage

• Ingredients relate to those ingredients used in product.Materials may include packaging consumables

• Bread styles and types include but are not limited tosours, flat breads, ryes, and continental breads

• Where recurrence of a problem cannot be prevented,procedures should be established to minimise thelikelihood of recurrence and to identify any furtherincidents

• Typical process parameters include temperature, time,humidity, development/proving time


FDFRBDPB3A Diagnose and respond to product and process faults (bread)


EVIDENCE GUIDE


Ability to: • Access workplace information relating to troubleshooting• Select, fit and use personal protective clothing and/or

equipment• Use relevant observation and/or test methods to confirm

raw ingredient characteristics• Remove/isolate and report ingredients/materials of

unacceptable quality• Determine likely causes of unacceptable final product

relating to raw ingredients• Determine likely causes of unacceptable final product

relating to the process and/or storage conditions• Develop procedures to prevent or minimise the likelihood

of recurrence of the problem




Knowledge of: • Basic composition, characteristics and function of eachmain ingredient used. This includes:• form/grade of ingredient supplied• behaviour/changes occurring during processing• role and purpose

• Preparation requirements for use. This may includeconditioning fruit

• Bread styles, types and textures. This includes anawareness of the labelling requirements for types ofbread consistent with the Food Standards Code

• Impact of ingredient cost and yields on profit margin• Principles of processing techniques used to achieve

finished products. This includes:• wet and dry proof methods• types of mixers used• hand moulding• oven types, including method of steam generation• methods of delivering product to the oven

• Effect of typical reactions during mixing, development andbaking. This may include:• yeast activity• gluten development• browning and caramelisation• gelatinisation as it occurs in different dough types

• Formula balance and ingredient addition sequence• Impact of ingredient cost and yields on profit margin• Process parameters and their effect. This can include

starting and finishing temperatures of ingredients anddough; the amount of work input/mixing time; and factorssuch as time, temperature and humidity during eachproving stage, and during baking, depanning and cooling

• Storage and handling conditions for raw ingredients andfinished product

• Procedures for reworking or disposing of unacceptableproduct

• Factors that can affect shelf-life, including:• ingredients used• bread types• storage conditions• packaging• environmental factors





Pre-requisite units




• FDFRBPD2B Produce bread dough• FDFRBSM2B Scale and mould dough for intermediate

proof• FDFRBFM2B Conduct final mould and final proof• FDFRBBB2B Bake bread




• Production schedule• Recipe instructions• Raw materials specifications• Production equipment• Relevant OHS clothing and equipment• Troubleshooting advice where available• Documentation and recording requirements and

procedures• Sampling schedules and test procedures and equipment


required





FDFRBDPC3A Diagnose and respond to product andprocess faults (pastry, cake and cookies)

Unit Descriptor This is a Specialist unit. It builds on the problem solving skillsdeveloped in operational units and provides technical competencies tosupport problem solving relating to pastry, cake and cookie production.

Prerequisite Unit(s) FDFRBDC2B Decorate cakes and cookiesFDFRBBC2B Bake sponges, cakes and cookiesFDFRBPC2B Produce sponge, cake and cookie batterFDFRBBP2B Bake pastry productsFDFRBFF2B Form and fill pastry productsFDFRBPF2B Prepare fillingsFDFRBPP2B Produce pastry



1. Identify causes ofunacceptable productquality

1.1 Unacceptable products are analysed to determine cause1.2 Process parameters and reactions which occur during

processing are monitored

2. Take corrective actionaccording to workplaceprocedures

2.1 Corrective action is taken to remove unacceptable productand prevent recurrence of the problem according toworkplace procedures

2.2 Corrective action is recorded according to workplaceprocedures and food safety program


FDFRBDPC3A Diagnose and respond to product and process faults (pastry, cake and cookies)


RANGE STATEMENT




• Raw materials include those used to manufacture pastry,cake and cookies

• Causes of unacceptable quality may relate to rawmaterials, processing and/or storage

• Ingredients relate to those ingredients used in product.Materials may include packaging consumables

• Where recurrence of a problem cannot be prevented,procedures should be established to minimise thelikelihood of recurrence and to identify any furtherincidents

• Typical process parameters include temperature, time,humidity, development/proving time

EVIDENCE GUIDE


Ability to: • Access workplace information relating to troubleshooting• Select, fit and use personal protective clothing and/or

equipment• Use relevant observation and/or test methods to confirm

raw ingredient characteristics• Remove/isolate and report ingredients/materials of

unacceptable quality• Determine likely causes of unacceptable final product

relating to raw ingredients• Determine likely causes of unacceptable final product

relating to the process and/or storage conditions• Develop procedures to prevent or minimise the likelihood

of recurrence of the problem




Knowledge of: • Basic composition, characteristics and function of eachmain ingredient used. This includes:• form/grade of ingredient supplied• behaviour/changes occurring during processing• role and purpose

• Preparation requirements for use. This may includeconditioning fruit and bringing ingredients to the requiredtemperature

• Styles, types and textures of finished products• Impact of ingredient cost and yields on profit margin• The purpose and effect of each production stage. For

pastry this includes:• all-in, french, rolled in and short dough methods• mixing• blocking• laminating• sheeting• shape forming• filling preparation• methods of assembly and finishing

• For cakes and cookies this includes:• batter preparation methods including flour batter, sugar

batter, all in and pre-mix methods• methods of aeration including mechanical and

chemical methods• sponge preparation methods• baking methods. This may include boiling, steaming

and baking• browning and caramelisation• methods of assembly and finishing

• Effect of typical reactions during mixing and baking. Thisvaries depending on product range. For pastry it mayinclude:• lift• shrinkage• dough development• gelatinisation• For cakes and cookies it may include:• emulsification• aeration - this includes the role of eggs in aeration• browning and caramelisation

• Formula balance and ingredient addition sequence• Impact of ingredient cost and yields on profit margin• Recipe and preparation requirements relevant to product

type. This can include starting and finishing temperaturesof ingredients and dough; the amount of workinput/mixing time; and factors such as time, temperatureand humidity during each proving stage, and duringbaking, depanning and cooling

• Storage and handling conditions for raw ingredients andfinished product

• Procedures for reworking or disposing of unacceptableproduct




• Factors that can affect shelf-life, including:• product type• ingredients used• preparation methods• storage conditions• packaging• environmental factors


Pre-requisite units


• FDFRBPP2B Produce pastry• FDFRBPF2B Prepare fillings• FDFRBFF2B Form and fill pastry products• FDFRBBP2B Bake pastry products• FDFRBPC2B Produce sponge, cake and cookie batter• FDFRBBC2B Bake sponges, cakes and cookies• FDFRBDC2B Decorate cake and cookie






• Production schedule• Recipe instructions• Raw materials specifications• Production equipment• Relevant OHS clothing and equipment• Troubleshooting advice where available• Documentation and recording requirements and

procedures• Sampling schedules and test procedures and equipment


required





FDFRBFD2B Freeze doughUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the skills and knowledge required to ability to freeze and thaw breaddough and other yeast-raised products. This unit applies to operating inan in-store or retail bakery environment.



1. Prepare to freeze dough 1.1 Dough freezing requirements are identified1.2 Freezers are set to meet parameters for snap freezing and

for storage1.3 Frozen dough meets freezing specifications

2. Store frozen dough 2.1 Storage conditions retain quality characteristics of frozendough

2.2 The freezing processes are monitored to ensure thatproduct meets food safety and quality requirements

3. Thaw frozen dough 3.1 Thawed dough meets food safety and qualityrequirements

3.2 Unacceptable dough is identified, rectified and/or removed3.3 Waste is disposed of according to workplace procedure3.4 Housekeeping standards are maintained in the workplace

RANGE STATEMENT





• Freezing equipment includes snap freezing equipmentsuch as blast freezers and storage freezers

• Dough that is frozen may be either made up or proveddough. Frozen dough that has not been proved requiresan additional step of conditioning before baking. Thisdoes not apply to proved dough


FDFRBFD2B Freeze dough


EVIDENCE GUIDE


Ability to: • Access freezing requirements for dough type• Set equipment to meet the parameters for snap freezing

and for storing dough• Transfer dough to snap freezer. Transfer method must

ensure minimal damage to dough structure. This isparticularly critical where frozen dough is already proofed

• Monitor equipment to confirm that freezing parametersare met

• Package snap frozen dough for freezer storage asrequired to prevent moisture loss

• Transfer snap frozen, packaged dough to frozen storage• Thaw dough as required for use• Maintain workplace records as required• Maintain work area to meet housekeeping standards




Knowledge of: • Basic principles of freezing dough. This includes anunderstanding of what occurs to dough during snapfreezing and storage stages

• Basic understanding of the freezing equipment used,freezing capacity and the effect of freezing method onproduct

• Different handling requirements of made up and proofeddoughs to preserve the dough structure

• Purpose and characteristics of packaging liners used topack frozen dough

• Procedures for maintaining temperature parameters offreezing equipment. This includes procedures to befollowed when loading and removing dough to preservetemperature conditions

• Storage patterns to make efficient use of space, allow forproduct rotation and minimise temperature fluctuations

• Food safety issues that can result from temperatureabuse

• The significance of timeliness when both freezing andthawing dough

• Optimal storage times• The significance of variables such as dough type and size

on freezing and thawing processes• Procedures for efficiently thawing frozen product and the

consequences of slow thawing• The effect of freezing/thawing on the quality of the final

product• Inspections/control points used to confirm that product

meets quality requirements and related monitoringrequirements


procedures


Pre-requisite units



This unit should be assessed together with core units and other unitsof competence relevant to the function or work role.






• Work procedures including advice on relevant freezing,storing and thawing requirements, safe work practices,food safety, quality and environmental requirements

• Product specifications and related inspection/controlpoints

• Freezing equipment• Packaging materials and liners as required• Dough• Personal protective clothing, equipment and material


required





FDFRBFF2B Form and fill pastry productsUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the skills and knowledge required to form pastry and deposit fillings intoa pastry shell or onto a pastry sheet which may then be toppedaccording to product requirements. This unit applies to form and fillprocesses in an in-store or retail bakery environment.



1. Prepare to fill and formpastry products

1.1 Pastry and fillings are confirmed and available to meetproduction requirements

1.2 Forming and filling equipment and/or utensils are availableand ready for use

1.3 Equipment is checked to confirm readiness for use

2. Form and fill pastryproducts

2.1 Pastry is rolled and shaped to meet product requirements2.2 Pastry is filled to meet product requirements2.3 Tops and/or finishes are applied as required2.4 Filled pastry product meets food safety and quality

requirements2.5 Unacceptable product is identified, rectified or reported




FDFRBFF2B Form and fill pastry products


RANGE STATEMENT





• Forming, filling, depositing and trimming of pastryproducts may be done manually or mechanically

• Equipment may include moulds, tins and trays anddepositing equipment

• Fillings may be sweet or savoury, hot or cold• Milk and egg washes may be applied prior to baking.

Glazes and sugar may be applied after baking.




EVIDENCE GUIDE


Ability to: • Access workplace information to identify productionrequirements

• Confirm that pastry types and fillings match productrequirements

• Confirm that equipment is clean and in operating order.This includes confirming that trays and tins are availableas required

• Prepare pastry and fillings for use. This may include:• rolling pastry• loading fillings into hopper and setting automatic

dispensing equipment• bringing fillings to required temperature

• Form product shape• Dispense fillings within acceptable volume, weight and

placement parameters• Apply tops, coding and/or toppings according to product

requirements• Trim pastry keeping bottom and top pastry separate• Include reworked pastry according to workplace

procedures• Monitor the forming and filling process to ensure that

quality standards are met. This can involve monitoring:• pastry thickness• alignment of deposited filling or accuracy of manual

positioning• amount and/or rate of filling deposited• product weight• enclosure of pastry product by forming, rolling or

covering with a pastry top to form seal• application of washes (before baking) or glaze and

toppings (after baking)• appearance (size and shape)

• Take corrective action so that product quality standardsare met





Knowledge of: • Basic principles of pastry forming and filling• Acceptable standards for equipment/utensils used. This

includes an understanding of cleaning requirements, andsigns of wear or unacceptable damage

• Quality requirements of filled pastry products. This caninclude appearance, weight, and seal as required byproduct

• Types of pastry suitable for use as tops and bottoms andin different products

• Procedures for inclusion of rework. This can include anunderstanding of appropriate uses of rework; maximumnumber of batches that can contain rework before scrapis discarded; and importance of ensuring rework pastry isnot contaminated by filling materials, other pastry types orother forms of contamination

• Procedure for preparing and applying washes and glazesas required for product

• The effect of variables such as filling temperature onfinished product, and product temperature on glazingapplication


• Inspections/control points used to confirm that productmeets quality requirements, and related monitoringrequirements


procedures


Pre-requisite units







• Recipe/decorating instructions• Product specifications and related inspection/control

points• Forming and filling equipment as required by product type• Shells/cases to be filled and fillings• Personal protective clothing, equipment and material


required




FDFRBFM2B Conduct final mould and final proofUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the principles, equipment and procedures used to mould dough to finalshape, place dough in tins or on baking surfaces and conduct finalproof in an in-store bakery or retail baking environment.



1. Mould dough and divide tomeet productrequirements

1.1 Dough is moulded to final shape1.2 Dough is placed in tins or on baking surfaces as required1.3 Dough meets specifications1.4 Unacceptable final proofed dough is identified, removed or

rectified and/or reported


2.2 Waste is disposed of according to workplace procedure2.3 Baked product meets food safety and quality requirements2.4 Housekeeping standards are maintained in the workplace


FDFRBFM2B Conduct final mould and final proof


RANGE STATEMENT





• Dough may be manually or mechanically moulded orshaped using moulding and rounding equipment. Otherequipment required is a final proofer

• Dough has undergone an intermediate proof stage priorto final moulding and proof

• Final proof may be wet or dry• Applying finishings can include methods such as dusting,

cutting, spraying and applying toppings• Confirming that tins/trays are ready for use involves

checking that tins/trays are greased and prepared to therequired standard and that hygiene and sanitationstandards are met

• Baking surfaces depend on workplace equipment andprocedures and can include tins, slippers, trays and soleof the oven




EVIDENCE GUIDE


Ability to: • Access workplace information to identify final mouldingand proofing requirements

• Confirm the required quantity of dough is available• Confirm that tins and/or baking surfaces are available and

ready for use• Carry out final mould. This may be done manually or by

using moulding and rounding equipment• Tin or place dough on baking surfaces as required• Conduct final proof of dough. Proofer settings are set to

allow the required development/proofing time andconditions such as temperature and humidity

• Prepare dough for baking. This can include applyingfinishings, positioning lids on tins according to productrequirements and shaping specialty breads

• Monitor dough volume and maturity• Visually check the appearance of finished products and

confirm that finishings are applied to meet qualityrequirements

• Identify, correct and/or remove unacceptablesized/shaped dough

• Clean equipment to meet hygiene standards• Maintain workplace records as required• Maintain work area to meet housekeeping standards

Knowledge of:

• How dough shape/size affects the final product• Requirements of the final proof process. This includes the

importance of relative humidity and temperature onproofing stage

• Purpose and procedures for conducting a wet or dry proof• Required characteristics of proofed dough such as size,

height, texture and appearance• Moulding techniques to achieve required product shape

for untinned bread products• Settings, operational requirements and safety features of

equipment used• Causes of variation and corrective action required• Control points and related monitoring requirements• OHS hazards and controls• Waste handling and cleaning requirements


Pre-requisite units









• Personal protective clothing and equipment• Work procedures including advice on relevant final mould

and proof requirements, safe work practices, food safety,quality and environmental requirements

• Baking instructions• Specifications, control points and processing settings• Final moulding and proofing equipment• Bread dough that has been scaled, moulded and

undergone intermediate proof• Personal protective clothing, equipment and material


required





FDFRBFP1B Finish productsUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the skills and knowledge required to assemble baked products andprepare and apply sweet fillings, icing and toppings, simple decorationand related presentation techniques used to finish cakes, pastries andbread-based products.



1. Prepare to finish products 1.1 Ingredients are confirmed and available to meet finishingrequirements

1.2 Equipment is checked to confirm readiness for use1.3 Finishing materials are prepared to meet product finishing

requirements

2. Assemble and finishproducts

2.1 Finishing materials are applied to meet presentationrequirements

2.2 Finished product meets presentation requirements2.3 Unacceptable product is identified, rectified or reported2.4 Products are assembled to meet customer and quality

requirements2.5 Housekeeping standards are maintained in the workplace


FDFRBFP1B Finish products


RANGE STATEMENT




• Workplace information can include verbal or writtenoperating procedures, specifications, productionschedules and batch/recipe instructions

• Finishing materials include but are not limited to fresh,mock or butter cream; icing sugar; glazes and similarfillings and coverings

• Finishing techniques may include application of icings,simple piping, placement and covering and preparation ofcakes ready for final decoration. Typical equipmentincludes piping bags and nozzles, mixing bowls andapplication utensils such as spatulas. Other finishingmethods can include filling, rolling and slicing product

• Simple decorating is done to a given specification anddoes not include design




EVIDENCE GUIDE


Ability to: • Access workplace information to identify finishingrequirements

• Confirm condition, type, quality and quantity ofingredients and prepared finishing materials

• Confirm that required fillings, toppings and finishingmaterials are available

• Confirm that equipment required is available, clean and fitfor use

• Mix or prepare finishing materials as required. This mayinclude weighing or measuring ingredients to recipespecifications

• Assemble product and apply fillings and finishingmaterials. Assembly requirements depend on product.Finishing methods can include:• assembling multi-layered products• prepare a cake ready for icing• spreading materials evenly and consistently• selecting correct piping bag nozzle and controlling

piping• cutting product into even size slices

• Take corrective action to ensure that finished productmeets quality standards

• Clean equipment and utensils to meet hygiene standards• Complete workplace records as required• Maintain work area to meet housekeeping standards

Knowledge of: • Basic principles of assembling products and preparingand applying fillings and decorative finishes

• Recognition of ingredients and storage requirements• Required characteristics of prepared finishing materials• Acceptable standards for equipment/utensils used. This


• The effect of variables such as temperature of the producton the application of finishings

• Application and decoration techniques such as simplepiping and placement

• Product presentation and storage requirements. This caninclude an understanding of refrigeration, freezing andshelf-life

• Causes of unacceptable finishes and corrective actionrequired

• OHS hazards and controls





Pre-requisite units



This unit should be assessed together with core units and otherunits of competence relevant to the function or work role. Inaddition, the following optional or ancillary unit may berelevant:




• Personal protective clothing and equipment• Work procedures including advice on relevant finishing


• Recipe for preparation of finishing materials whererequired and decoration instructions

• Final product specifications and related inspection/controlpoints

• Finishing application utensils and equipment as requiredby product

• Product to be decorated, fillings and finishingmaterials/ingredients

• Personal protective clothing, equipment and materialsafety data sheets as required






FDFRBGT3A Produce and decorate gateaux and tortesUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the skills and knowledge required to plan, produce and decorate arange of multi-layered gateaux and tortes.

Prerequisite Unit(s) FDFRBPC2B Produce sponge, cake and cookie batterFDFRBPP2B Produce pastryFDFRBPM2B Produce meringue-based productsFDFRBCP2B Produce choux pastryFDFRBPF2B Prepare fillingsFDFRBDC2B Decorate cakes and cookiesFDFRBBC2B Bake sponges, cakes and cookiesFDFRBBP2B Bake pastry products



1. Plan and sequencepreparation of gateauxand tortes

1.1 Recipe is selected to meet product/customer requirements1.2 Preparation and production stages are planned

2. Prepare sponges andother bases for use ingateaux and torteproduction

2.1 Ingredients are selected to suit recipe specifications2.2 Bases are prepared meet product requirements2.3 Product is baked to meet quality requirements

3. Prepare fillings andfinishings for use ingateaux and tortes

3.1 Recipe is selected appropriate to preparation of fillingsand finishings for final product

3.2 Fillings and finishings are prepared according to reciperequirements

3.3 Fillings and coatings meet food safety and qualityrequirements

4. Assemble gateaux andtortes

4.1 Bases are prepared for assembly4.2 Bases and fillings are assembled to meet recipe

specifications4.3 The product is covered to meet recipe specifications

5. Finish and decorategateaux and tortes

5.1 Decorating materials are prepared to meet customerrequirements

5.2 Decorations and decorating materials are applied to meetcustomer requirements

5.3 Final product is presented to meet food safety andcustomer requirements

6. Cost and price finalproduct

6.1 Product ingredients are costed6.2 Production costs are estimated6.3 Product is priced within business pricing policy6.4 Actual costs are measured against estimated costs


FDFRBGT3A Produce and decorate gateaux and tortes


RANGE STATEMENT





• Bases may be produced in sheets or forms• Note that this unit specifies minimum finishings, fillings

and final product preparation requirements. Where thesehave been covered in earlier units of competency, theseaspects of the unit do not need to be reassessed




EVIDENCE GUIDE


Ability to: • Given product description and/or customer request, selectrecipe to meet product/customer requirements

• Price ingredients for use in product• Estimate cost of production• Select ingredients to meet recipe requirements• Review recipe to identify preparation and production

stages and establish a plan to sequence each step sothat ingredients are prepared and available in optimumcondition for use

• Produce bases to meet recipe requirements. This mustinclude but is not limited to producing:• sponge bases• meringue bases• pastry bases

• Prepare fillings, finishings and toppings to meet reciperequirements. This must include but is not limited topreparing:• mousse• ganache• chocolate• creams/butter creams/pastry creams• jams• glazes• custard• fruit• cream cheese• fondant• nougat

• Prepare bases for assembly. This includes cutting ortrimming bases as required to meet product requirements

• Assemble product to achieve the required layers andshape to meet quality requirements

• Cover gateaux and tortes to meet recipe requirementsand to achieve the required finish and appearance

• Finish and decorate the final product. This must includebut is not limited to finishing and decorating:• chocolate-themed gateaux/tortes• fruit-themed gateaux/tortes

• Store ingredients, finished and part-finished product inappropriate storage conditions

• Clean equipment and utensils to meet hygiene standards• Maintain workplace records as required• Maintain work area to meet housekeeping standards• Provide customer advice on storage, preparation and

portioning as appropriate to product type and intendeduse. Advice must be consistent with food safety andquality requirements

• Measure actual production costs against estimate andaccount for any variation




• Determine an appropriate price for final products

Knowledge of: • Ingredient characteristics, purpose and preparationrequirements. This builds on knowledge developed inpre-requisite units and includes but is not limited to aknowledge of:• scope to substitute or vary ingredients in a recipe• the effect of ingredients on shelf-life and food safety• characteristics of essences and liqueurs used in baking• the role, preparation requirements and uses of

additives including colours, flavours and stabilisers• Optimum storage conditions and shelf-life for ingredients,

fillings and finishings and related sequencing andpreparation requirements

• Optimum conditions for use of ingredients, fillings andfinishings. This varies according to ingredient type andtypically includes temperature and may include moisturecontent

• The effect of refrigeration and freezing on finished andpart-finished product as appropriate to product type

• Optimum storage conditions for the finished product priorto sale

• Storage, handling and preparation requirements of thefinished product. This includes an understanding ofinformation to be provided to consumers as appropriate toproduct type and consistent with food safety requirements

• Ingredient suppliers and pricing information• Methods of estimating fixed and variable costs, and profit

margin to determine sale price range• Basic awareness of trade practice issues when pricing

products• Business policy and parameters in pricing products


Pre-requisite units


• FDFRBBP2B Bake pastry products• FDFRBBC2B Bake sponges, cakes and cookies• FDFRBDC2B Decorate cakes and cookies• FDFRBPF2B Prepare fillings• FDFRBCP2B Produce choux pastry• FDFRBPM2B Produce meringue-based products• FDFRBPP2B Produce pastry• FDFRBPC2B Produce sponge, cake and cookie batter









• Recipes and customer specifications• Production equipment appropriate to product type• Materials/ingredients to meet recipe requirements• Ingredient pricing information• Personal protective clothing, equipment and material


required





FDFRBPC2B Produce sponge, cake and cookie batterUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the principles, equipment and procedures used to produce a range ofcake, sponge and cookie batters in an in-store bakery or retail bakingenvironment.



1. Prepare sponge, cake andcookie batter



1.3 Equipment is checked to confirm readiness for use1.4 Mixing equipment is set and operated to meet recipe

requirements1.5 Ingredients are loaded into the mixer to meet recipe

requirements1.6 Batter meets specifications1.7 Prepared batter is deposited into tins/onto papers




FDFRBPC2B Produce sponge, cake and cookie batter


RANGE STATEMENT





• Batters for cakes, sponges and cookies may be preparedfrom scratch or by using pre-mixes

• Typical ingredients include but are not limited to flour,sugar, shortenings and margarines, eggs, fruit and flavourenhancing ingredients

• Equipment may include tins and trays, mixers, sieves,hydraulic lifting, depositing equipment

• Confirming equipment status involves checking thathygiene and sanitation standards are met, all safetyguards are in place, equipment is operational andrequired attachments are fitted. In the case of spongeproduction, this includes ensuring bowls and utensils arefree of all fat residues




EVIDENCE GUIDE



• Confirm condition, type, quality and quantity ofingredients. This includes selecting shortening type tomeet recipe and ambient temperature requirements

• Weigh, scale or meter ingredients as required• Calculate yield based on given batch weight and/or main

ingredient weight, according to workplace practices• Confirm equipment status and condition• Transfer ingredients to the mixer in the required

sequence• Set mixing equipment to meet production requirements.


• Operate and monitor the mixing process. This can includemonitoring:• mixing time and speed• ingredient and finished batter temperature• batter consistency, appearance and texture

• Identify batter that does not meet quality requirementsand take necessary corrective action

• Prepare tins/trays, liners and papers as required• Deposit, extrude or spread batter to meet product and

volume/weight requirements• Clean equipment and utensils to meet hygiene standards• Maintain workplace records as required• Maintain work area to meet housekeeping standards




Knowledge of: • Basic principles of cake, sponge and cookie making• Ingredient characteristics and purpose in the final

product. This includes a knowledge of flour types, sugargrades, shortening and emulsifiers, and fresh and/or pulpegg. It may also include a basic understanding of pre-mixcomposition


• Ingredient storage requirements• Methods used to prepare cake batter• Physical and chemical methods used to aerate batter• Significance of factors such as temperature of batter on

final product• Factors affecting sponge-making• Required characteristics of batter• Process requirements. This may include:

• mixing times and speeds• batter specifications


• Methods used to deposit batter including use of releaseagents as required

• Causes of variation and corrective action required• Control points and related monitoring requirements• OHS hazards and controls• Waste handling and cleaning and procedures


Pre-requisite units








points• Production equipment. This can include mixing, and

depositing, equipment as required by product type• Materials/ingredients• Personal protective clothing, equipment and material


required




Assessment requirements • For information on how to assess this competencystandard and who can assess, refer to the AssessmentGuidelines for this Training Package.




FDFRBPD2B Produce bread doughUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the principles, equipment and procedures used to produce a range ofdough types including white, brown, wholemeal and grain doughs in anin-store bakery or retail baking environment.



1. Prepare to mix dough 1.1 Ingredients are confirmed and available to meet productrequirements

1.2 Equipment is checked to confirm readiness for use1.3 Ingredients are weighed and/or measured to meet recipe

requirements

2. Prepare a range of doughtypes

2.1 Ingredients are loaded into the mixer to meet reciperequirements

2.2 Dough mixing equipment is set and operated to meetrecipe requirements

2.3 Dough meets specifications2.4 Unacceptable dough is identified, rectified and/or reported




FDFRBPD2B Produce bread dough


RANGE STATEMENT





• Typical ingredients include but are not limited to wheatflour, water, salt, yeast, shortenings, bread improvers andadditional ingredients such as rye flour, sours, fruit,spices, grains and fibre

• Equipment may include mixers, sieves, weighing,metering and lifting equipment




EVIDENCE GUIDE



• Confirm condition, type, quality and quantity ofingredients

• Confirm that equipment is clean and ready for operation• Weigh, scale or meter ingredients as required• Calculate yield based on a given batch weight or flour

weight according to workplace practice• Transfer ingredients to the mixer in the required

sequence• Set mixing equipment to meet recipe requirements• Adjust water temperature to meet final finished dough

temperature requirements• Operate and monitor the mixing process. This may

include monitoring:• dough consistency feel and texture• ingredient and finished dough temperature• dough development/bulk fermentation time

• Take corrective action as required to ensure doughrequirements are met


Knowledge of: • Basic principles of dough making• Ingredient characteristics and purpose in dough. This

includes an understanding of flour quality and thecomponents of wheat flour


• Methods used to confirm accuracy of measuringequipment used. This includes taring scales

• Ingredient storage requirements• Significance of factors such as dough temperature, the

amount of work input/mixing time, gluten development,water addition, yeast activity and consistency of dough

• Purpose and time required to allow dough to rest/fermentfollowing mixing

• Required characteristics of dough• Causes of variation and corrective action required• Settings, operational requirements and safety features of

mixing equipment• Control points and related monitoring requirements• OHS hazards and controls• Waste handling and cleaning and procedures





Pre-requisite units






• Work procedures including advice on relevant doughpreparation requirements, safe work practices, foodsafety, quality and environmental requirements


points• Mixing equipment• Materials/ingredients• Personal protective clothing, equipment and material


required





FDFRBPD3B Participate in product developmentUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the skills and knowledge required to evaluate retail and/or in-storebakery products and modify existing recipes to produce new products.Responsibility for approving new products is typically at a higher level.



1. Research opportunities fornew product

1.1 Market characteristics are identified1.2 Opportunities for product development are matched to

market

2. Develop a productproposal to meet marketopportunity

2.1 Evaluate competing products2.2 Adapt existing formulas to produce new product2.3 Determine method of assembly and presentation2.4 Estimate the cost of production2.5 Present product concept

RANGE STATEMENT



• New products are based on known formulas/recipes• Evaluation of competing products relies primarily on

observation and taste

EVIDENCE GUIDE


Ability to: • Identify competitors• Identify local demography relevant to retail bakery

products• Determine product development opportunities• Identify the main ingredients and method used to produce

competing products• Modify existing formulas/recipes to produce required

product• Determine product assembly and presentation• Cost product• Present product proposal


FDFRBPD3B Participate in product development


Knowledge of: • Sources of information on local market, product rangeand performance of similar products

• Expected quality and taste of products to meet businessand customer expectations

• Basic composition and methods used to produce retailbakery products relevant to the business

• Availability of ingredients and processing equipmentrequired by new product

• Food safety issues related to production, preparation,presentation and storage of product

• Methods of gaining customer feedback. Examples includeconducting tastings

• Methods of estimating fixed and variable costs, and profitmargin to determine sale price range

• Basic awareness of trade practice issues when pricingproducts

• Communication skills required to research and presentinformation


Pre-requisite units






• Local market for which product is to be developed• Existing product range, ingredients, recipes/formulas,

equipment and methods used in the workplace• Product development procedures used in the workplace



FDFRBPD3B Participate in product development


FDFRBPF2B Prepare fillingsUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the skills and knowledge required to prepare a range of fillings for usein cake, bread and pastry products in an in-store bakery or retail bakingenvironment.



1. Prepare ingredients foruse


1.2 Equipment is checked to confirm readiness for use1.3 Ingredients are weighed and/or measured to meet recipe

requirements1.4 Ingredients are prepared for use in fillings

2. Prepare fillings 2.1 Fillings are prepared to meet recipe requirements2.2 Fillings meet food safety and quality requirements2.3 Unacceptable ingredients or fillings are identified, rectified

and/or reported




FDFRBPF2B Prepare fillings


RANGE STATEMENT





• Savoury filling ingredients include but are not limited tominced or diced raw meat (including chicken),vegetables, eggs, starches and other ingredients asrequired for use in products such as pies, sausage rolls,pasties, quiches and other products

• Sweet fillings include but are not limited to fruit, syrup,jam, custard, cream and starches

• Preparation of ingredients for use in fillings can includethawing, mincing, peeling, slicing, dicing and cooking




EVIDENCE GUIDE




• Weigh, scale or meter ingredients as required• Confirm equipment status and condition• Prepare ingredients as required. This may include

thawing or conditioning pre-prepared ingredients and/orpreparing raw ingredients for use, and preparing solutionsfor addition such as dissolving starch for use in a mixture

• Combine and process fillings. This may includemonitoring:• quality, quantity and sequencing of ingredient addition• blending/mixing process• cooking times and temperatures• filling characteristics (colour, texture, smell, viscosity)

• Take corrective action so that fillings meet qualitystandards





Knowledge of: • Basic principles of filling preparation• Differences in filling types for different product types• Ingredient characteristics and purpose in filling. This

includes an awareness of types of thickeners used forfilling types

• Methods used to confirm accuracy of measuringequipment used. This includes taring of scales

• Methods used to prepare fillings in the workplace• Quality characteristics and uses of fillings• Process requirements such as:

• time and temperature requirements relating to thawing,reheating, cooling (of cooked food) and cooking asrequired

• storing/holding requirements• cooking times and temperatures• reconstituting dry ingredients


• Control points and related monitoring requirements. Thisincludes an awareness of time and temperatureparameters for cooking

• Causes of variation and corrective action required• OHS hazards and controls• Storage requirements for prepared fillings. This can

include an understanding of refrigeration, freezing andshelf-life

• Contamination (including cross-contamination) risksassociated with ingredients/processes used

• Waste handling and cleaning and procedures


Pre-requisite units






• Work procedures including advice on relevant fillingpreparation requirements, safe work practices, foodsafety, quality and environmental requirements


points• Filling preparation equipment as required by product type• Materials/ingredients• Personal protective clothing, equipment and material


required




FDFRBPM2B Produce meringue-based productsUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the principles, equipment and procedures used to producemeringue-based products in an in-store bakery or retail bakingenvironment.






1.3 Equipment is checked to confirm readiness for use1.4 Ingredients are added and mixed in the correct sequence

to meet recipe requirements1.5 Mix meets specifications

2. Shape or form product 2.1 Meringue is shaped to meet product requirements2.2 Meringue is topped and baked as required to meet recipe

requirements2.3 Product is baked as required by meringue type, to meet

finished product requirements2.4 Final product meets food safety and quality requirements2.5 Unacceptable dough is identified, rectified and/or reported




FDFRBPM2B Produce meringue-based products


RANGE STATEMENT





• Base ingredients include egg white and sugar• Eggs may be mechanically or manually beaten• Equipment may include mixing bowls, whisks, mechanical

mixers, ovens and piping bags• Meringues may be baked or unbaked depending on

recipe requirements




EVIDENCE GUIDE




• Prepare ingredients for use. This may include separatingegg whites or reconstituting powdered whites andpreparing sugar or sugar syrup as required by product

• Beat egg whites to achieve the required texture. This maybe done manually or using mixing equipment

• Add remaining ingredients in the required sequence andstage to meet recipe requirements

• Monitor the appearance and consistency of mix andensure that all ingredients are added

• Take corrective action as required so that meringuemeets quality standards

• Shape meringue to meet product requirements. This maybe done by piping or manually shaping

• Pipe or drop meringue to meet product requirements• Apply toppings as required by product• Bake meringue to remove moisture and achieve required

appearance (applies to baked meringues only)• Clean equipment and utensils to meet hygiene standards• Maintain workplace records as required• Maintain work area to meet housekeeping standards


• Finish products




Knowledge of: • Basic principles of making meringues• Ingredient characteristics and purpose. This includes an

understanding of how the preparation and conditioning ofwhites affects whisking


• Process requirements. This may include:• cleaning/degreasing bowls and utensils• mixing times and speeds• baking as required• cooling

• Required characteristics of meringues, uses and relatedprocessing methods


• Significance of variables such as:• time and speed at each stage of mixing• rate and sequence of ingredient addition• baking times and temperatures for final product

• Product presentation and storage requirements. Thisincludes an understanding of the importance of thoroughcooling prior to storing and potential effects of moistureon product

• Causes of variation and corrective action required• Control points and related monitoring requirements• OHS hazards and controls• Waste handling and cleaning and procedures


• Preparing and applying decorations to finish products


Pre-requisite units









• Work procedures including advice on relevant meringueproduct preparation requirements, safe work practices,food safety, quality and environmental requirements


points• Mixing bowls and utensils, piping equipment and oven

equipment as required by product type• Materials/ingredients• Personal protective clothing, equipment and material


required





FDFRBPP2B Produce pastryUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the principles, equipment and procedures used to produce pastry andshortbread in an in-store bakery or retail baking environment. This unitcovers all pastry types with the exception of choux pastry and mayinclude the steps of blocking and laminating according to pastryrequirements.






1.3 Equipment is checked to confirm readiness for use1.4 Mixing equipment is set and operated to meet recipe

requirements1.5 Ingredients are loaded into the mixer to meet recipe

requirements1.6 Mix meets specifications

2. Block and laminate pastryas required

2.1 Pastry is blocked to meet dough break requirements2.2 Pastry is laminated and folded to meet product

requirements2.3 Pastry meets food safety and quality requirements2.4 Unacceptable pastry is identified, rectified and/or reported




FDFRBPP2B Produce pastry


RANGE STATEMENT





• Ingredients include but are not limited to flour, shortening,sugar, salt and water

• Equipment may include mixers, sieves, lifting equipment,and dough break equipment for laminating

• Shortening may be added to the mixer or worked into thedough manually

• Folding of pastry is typically in half or book folds• Lamination does not apply to short paste and pie bottom

paste




EVIDENCE GUIDE



• Confirm condition, type, quality and quantity ofingredients. This includes selecting shortening type tomeet recipe and ambient temperature requirements

• Weigh, scale or meter ingredients as required• Calculate yield based on given batch weight and/or main

ingredient weight, according to workplace practices• Confirm equipment status and condition• Set mixing equipment to meet production requirements.



• Monitor the appearance and consistency of mix andensure that all ingredients (including shortening) areadded

• Block pastry as required, to suit dough break capacity• Roll out pastry dough and add shortening if not already in

the mix• Set aside for further use or proceed to laminate• Laminate and fold pastry to meet product requirements• Take corrective action as required so that pastry meets

quality standards• Clean equipment and utensils to meet hygiene standards• Maintain workplace records as required• Maintain work area to meet housekeeping standards




Knowledge of: • Basic principles of pastry making• Ingredient characteristics and purpose in pastry. This

includes an understanding of shortening types, flourtypes, components and their effect on pastry quality

• Significance of factors such as shortening type andtemperature on final product


• Process requirements. This may include:• mixing times and speeds• appearance and consistency to be met• batching or scaling off pastry for blocking• pastry rolling and folding for pastry type• resting time

• Required characteristics of different types of pastry, usesand related processing methods


• Purpose and time required to allow pastry to rest• Product storage requirements. This can include an

understanding of refrigeration, freezing and shelf-life• Causes of variation and corrective action required• Control points and related monitoring requirements• OHS hazards and controls• Waste handling and cleaning and procedures


Pre-requisite units






• Work procedures including advice on relevant pastryproduct requirements, safe work practices, food safety,quality and environmental requirements


points• Mixing, rolling, blocking and laminating equipment as

required by pastry type• Materials/ingredients• Personal protective clothing, equipment and material


required




FDFRBPY2B Produce yeast-raised productsUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the skills and knowledge required to produce a range of yeast-basedbreads, cakes and pastries in an in-store bakery or retail bakingenvironment.



1. Prepare to mix dough 1.1 Ingredients are confirmed, available and conditioned orprepared to meet production requirements

1.2 Equipment is checked to confirm readiness for use

2. Prepare dough 2.1 Ingredients are loaded into mixer to meet reciperequirements

2.2 Mixing equipment is set and operated to meet reciperequirements

2.3 Dough meets product requirements

3. Bake/fry product 3.1 Dough is shaped for baking or frying3.2 The baking/frying process is operated to meet required

output3.3 Final product meets food safety and quality requirements3.4 Unacceptable product is identified, rectified and/or

reported


4.2 Waste is disposed of according to workplace procedure


FDFRBPY2B Produce yeast-raised products


RANGE STATEMENT





• Typical yeast-raised products include but are not limitedto danish pastries, croissants, savarin, brioche and friedbreads. They may be prepared from scratch or usingpre-mixes

• Typical ingredients include but are not limited to flour,yeast, sugar, fruit, shortening and emulsifiers

• Conditioning ingredients may include bringing to requiredtemperature and soaking dry ingredients

• Preparation and cooking methods vary according toproduct type. Some products require lamination. Typicalcooking methods include baking and frying. Finishingmethods can include filling, topping, glazing and soakingin syrup. Washes such as milk and egg may be appliedprior to cooking

• Typical equipment includes mixers, sieves, liftingequipment, extruders, depositors and/or rollers, ovensand frying equipment according to workplace practice andproduct requirements




EVIDENCE GUIDE




• Prepare ingredients as required. This may includeweighing, scaling or metering ingredients andconditioning ingredients such as dried fruit

• Confirm that equipment required is available, clean and fitfor use


• Set mixing equipment to meet recipe requirements.Settings may include:• selecting and fitting attachments• setting mixing speed and time

• Operate and monitor the mixing process. This can includemonitoring:• ingredient and finished dough temperature• dough development• dough consistency, feel and texture• addition of special ingredients such as dried fruit• selecting and fitting attachments

• Finish dough to meet product requirements. This mayinclude rolling, adding shortening if not already in the mix,laminating and folding

• Allow dough to proof• Prepare cooking trays• Deposit, extrude, roll or shape dough to meet product and

volume/weight requirements• Set up cooking equipment. This may include setting oven

temperatures, times and humidity and/or preparing deepfrying equipment

• Operate and monitor baking/frying process. This caninclude monitoring time, colour and appearance

• Cool and present finished product. This can includeplacing on cooling racks and slicing and applying glazesand/or sugar

• Calculate product yield based on given batch weightand/or main ingredient weight, according to workplacepractices

• Take corrective action so that quality standards are met• Clean equipment and utensils to meet hygiene standards• Complete workplace records as required• Maintain work area to meet housekeeping standards


• Finish products• Form and fill products




Knowledge of: • Basic principles of producing yeast-raised products• Ingredient characteristics, purpose in the product and

storage requirements. This includes a knowledge of flourtypes, sugar grades, shortening and emulsifiers and otheringredients used

• Required characteristics of finished products• Method used to calculate ingredient weights to meet

production and recipe requirements• Acceptable standards for equipment/utensils used. This


• Process requirements. This may include:• mixing times and speeds• purpose and time required to allow mix to proof• batter specifications• baking times and temperatures• oven settings

• Effect of variables such as ambient conditions on theproofing process, dough temperature, glutendevelopment, water addition, yeast activity andconsistency of dough


• Product presentation and storage requirements. This caninclude an understanding of refrigeration, freezing andshelf-life

• Inspections/control points used to confirm that productmeets quality requirements and related monitoringrequirements

• Causes of variation and corrective action required. Thisincludes an understanding of the role of sugar inbrowning

• OHS hazards and controls• Waste handling requirements. This can include methods

such as salting down waste to prevent yeast development• Cleaning requirements and procedures


• Preparing and applying decorations to finish products• Forming and filling products





Pre-requisite units



This unit should be assessed together with core units and otherunits of competence relevant to the function or work role. Inaddition, the following optional or ancillary unit may berelevant:





• Recipe instructions• Final product specifications and related inspection/control

points• Mixing, baking/frying equipment• Materials/ingredients• Personal protective clothing, equipment and material


required





FDFRBRD2B Retard doughUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the principles, equipment and procedures used to retard and recoverdough and other yeast-raised products in an in-store bakery or retailbaking environment.



1. Prepare to retard dough 1.1 Dough retardation requirements are identified1.2 Equipment is set to meet retardation parameters

2. Retard and recover dough 2.1 Dough is retarded to meet specification2.2 Equipment is set to meet dough recovery parameters2.3 Retarded and recovered doughs meet specification2.4 Unacceptable dough is identified, rectified and/or reported2.5 Housekeeping standards are maintained in the workplace

RANGE STATEMENT





• Dough retardation refers to a method of delaying doughfermentation by placing dough in a controlledenvironment

• Dough retarding equipment may combine retarding with arecovery/proofing stage or be used for retarding only


FDFRBRD2B Retard dough


EVIDENCE GUIDE


Ability to: • Access retardation requirements for dough type• Set equipment to meet the parameters for retarding

dough. This includes selecting time, temperature andhumidity

• Load dough into the retarder. This is done in a way thatminimises the delay between dough make up and loadinginto the retarder and follows dough rotation procedures sothat dough is not retarded for more than the optimal time

• Follow procedure to ensure retarding and recovery timesare met

• Monitor equipment to confirm that parameters are met• Where recovery is achieved using separate equipment,

allow sufficient rest time between recovery and proofer• Clean equipment and utensils to meet hygiene standards• Maintain workplace records as required• Maintain work area to meet housekeeping standards

Knowledge of: • Basic principles of retarding dough. This includes anunderstanding of what occurs to dough when it isretarded and recovered and how retardation works bycontrolling temperature to slow yeast fermentation

• The significance of variables such as time, temperatureand humidity on the dough retardation and recoveryprocess

• Where dough recovery is achieved using separateequipment, the significance of dough conditioning prior torecovery

• The effect of any delay in loading dough into the retarderon fermentation

• The effect of finished dough temperature on retardationprocess

• The effect of humidity on the dough surface and formationof skin on dough

• The significance of variables such as dough type and sizeon recovery time and conditions

• The effect of retardation on the quality of the final product• Optimal time for retarding dough and procedures to

ensure this time is met• Causes of variation and corrective action required• Control points and related monitoring requirements• OHS hazards and controls• Waste handling and cleaning and procedures





Pre-requisite units






• Work procedures including advice on relevant doughretardation and recovery requirements, safe workpractices, food safety, quality and environmentalrequirements


points• Dough retarding equipment and proofing equipment

(where not combined)• Dough• Personal protective clothing, equipment and material


required





FDFRBSM2B Scale and mould dough for intermediateproof

Unit Descriptor This is a Specialist unit developed for the retail baking sector. It coversthe principles, equipment and procedures used to divide and shapedough in an in-store bakery or retail baking environment. It includes anintermediate proof stage.



1. Scale and mould dough 1.1 Dough is scaled to meet production requirements1.2 Scaled dough meets weight requirements1.3 Dough is moulded to provide initial shape1.4 Unacceptable scaled and moulded dough is identified,

removed or rectified and/or reported


2.2 Waste is disposed of according to workplace procedure

RANGE STATEMENT





• Typical ingredients include but are not limited to wheatflour, water, salt, yeast, shortenings, bread improvers andadditional ingredients such as rye flour, sours, fruit,spices, grains and fibre

• Equipment may include mixers, sieves, weighing,metering and lifting equipment


FDFRBSM2B Scale and mould dough for intermediate proof


EVIDENCE GUIDE



• Confirm the required quantity of dough is available• Divide dough into pieces of the required weight• Round or mould dough to meet intermediate proof weight

requirements• Allow dough to develop for the required time

(intermediate proof)• Monitor size and shape of dough and skin formation on

dough during intermediate proof• Identify, correct and/or remove unacceptable

sized/shaped dough• Clean equipment and utensils to meet hygiene standards• Maintain workplace records as required• Maintain work area to meet housekeeping standards

Knowledge of: • The effect of dough shape/size on the final product• Purpose and time required to allow dough to develop• Methods used to confirm accuracy of measuring

equipment used• Required characteristics of proofed dough such as size,

height and appearance• Causes of variation and corrective action required• Settings, operational requirements and safety features of

dividing and rounding equipment• Causes of variation and corrective action required• Control points and related monitoring requirements• OHS hazards and controls• Waste handling and cleaning and procedures


Pre-requisite units









• Work procedures including advice on relevant scaling andmoulding for intermediate proof requirements, safe workpractices, food safety, quality and environmentalrequirements


points• Dividing, rounding and intermediate proof equipment

used in the workplace. In some workplaces these tasksare manually performed and do not involve the use ofequipment

• Dough• Personal protective clothing, equipment and material


required





FDFRBSP3B Plan and schedule productionUnit Descriptor This is a Specialist unit developed for the retail baking sector. It covers

the skills and knowledge required to plan and schedule work to meetproduction requirements in a retail bakery or in-store bakeryenvironment.



1. Establish productionrequirements

1.1 Identify sales history information1.2 Identify any special conditions that may affect production

requirements1.3 Estimate production requirements

2. Schedule production tomeet requirements

2.1 Calculate dough/batter types and volumes2.2 Schedule batches to meet customer requirements and

equipment capacity2.3 Communicate production schedule as required according

to workplace practice2.4 Product is available to customer demand in the required

quantities, at the required quality and at the required time

RANGE STATEMENT



• Sales history identifies the number of products sold overa given period. It may also indicate the pattern of salesover the course of a day

• Special conditions that may affect productionrequirements can include weather conditions and specialevents or occasions

• Matching equipment capacity includes taking account ofthroughput speed


FDFRBSP3B Plan and schedule production


EVIDENCE GUIDE


Ability to: • Identify relevant information such as sales volumes andpurchasing patterns and any conditions that couldinfluence sales

• Estimate how much and what type of product is requiredand the time it should be available. This estimate can befor one day or according to workplace requirements

• Estimate dough weight compared to finished productweight

• Determine optimum batch size, number and timing, takingaccount of process stages, equipment capacity andavailability of labour

• Produce or complete a production schedule coveringeach stage of the production process

• Regulate dough/batter maturity and proofing of yeastproducts so they arrive at the oven at the optimum timeand condition

• Develop a production schedule. Where a workplace hasan existing production schedule format, assessment canbe based on completing production schedule details.Where there is no established format, the assessee isrequired to produce a production schedule to describe adaily production requirement

Knowledge of: • Sources of information on sales performance, history andspecial events

• Methods used to regulate dough/batter maturation andproofing including formulation, temperature control andtime

• Production schedule formats and level of detail asappropriate to meet workplace scheduling requirements

• An overview of baking processes and stages to matchproduction to optimal timing and equipment capacity


Pre-requisite units








Assessment of this unit must occur in a real or simulatedworkplace. Such an environment must provide an opportunityfor the assessee to prepare or complete a daily productionschedule given:

• Sales performance, history and other relevant information• Product formulations• Formulae to calculate batch weight to finished product

weight• Process equipment and information on capacity





FDFSFGP2B Operate a grinding processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down processes such as grinding,rolling and breaking to reduce the particle size of grains and pulses.

Unit Sector Stockfeed Milling


1. Prepare the grindingequipment and processfor operation

1.1 Materials are confirmed and available to meet productionrequirements






2. Operate and monitor thegrinding process






2.6 Workplace housekeeping standards are maintained2.7 Workplace records are maintained according to workplace


3. Shut down the grindingprocess




FDFSFGP2B Operate a grinding process


RANGE STATEMENT





• Equipment used in the grinding process may includeconveyors/elevators, augers, magnets, fans, sieves,hammer mills, roller mills, breaker bars, and cyclones

• Materials include grains and pulses. Pulses are legumesand typically include peas, beans and lentils







EVIDENCE GUIDE




• Confirm supply of necessary materials and services to thegrinding process


• Operate stockfeed control panel to transfer and grindproduct

• Monitor and adjust the grinding process and equipmentoperation to achieve required outcomes. This may includemonitoring control points and conducting inspections asrequired to confirm process remains within specification,and running adjustments to hammer mills and roller mills

• Monitor supply and flow of materials to and from thegrinding process





• Complete workplace records as required• Demonstrate batch/product changeovers• Sort, collect, treat, recycle or dispose of waste• Maintain work area to meet housekeeping standards






Knowledge of: • Purpose and basic principles of the grinding process. Thisincludes a basic understanding of the characteristics ofmaterials which can be reduced to a suitable form forstockfeed

• Basic operating principles of equipment. This may includean operational understanding of main equipmentcomponents, bulk materials transfer systems andequipment, dust collection equipment, grinding equipmentoperating capacities and applications, and the purposeand location of magnets, sensors and related feedbackinstrumentation. It also includes knowledge of servicesrequired and action to take if services are not available

• Basic operating principles of process control. Thisincludes the relationship between control panels andsystems and the physical equipment

• The flow of the grinding process and the effect of productoutput on downstream processes

• Quality characteristics and uses of grinding processoutputs

• Effect of the grinding process on the end product• Effect of raw material characteristics on grinding process

performance• Operating requirements and parameters and corrective



• Techniques used to monitor the production process. Thismay include inspecting, measuring and testing asrequired by the process. It requires awareness ofinspection or test points (control points) in the processand the related procedures and recording requirements

• Contamination/food safety risks associated with thegrinding process and related control measures


• OHS hazards and controls including the risk of dustexplosion and an understanding of the limitations ofprotective clothing and equipment relevant to the workprocess





• Environmental issues and controls relevant to theprocess. This includes waste/rework collection and




handling procedures related to the process





Pre-requisite units









• Specifications, control points and processing parameters• Production schedule/batch instructions• Information on equipment capacity and operating

parameters• Grinding and related equipment and services• Stock required for the grinding process• Sampling schedules and test procedures and equipment



required

Assessment requirements For information on how to assess this competency standardand who can assess, refer to the Assessment Guidelines forthis Training Package




FDFSFPFP2A Operate a pelleting processUnit Descriptor This is a Specialist unit. It covers the skills and knowledge required to

set up, operate, adjust and shut down process equipment to compressmash into pellets and to finish pellets.

Unit Sector Stockfeed Milling


1. Prepare the pelletingequipment and processfor operation







2. Operate and monitor thepelleting and pelletfinishing process






2.6 Workplace housekeeping standards are maintained2.7 Workplace records are maintained according to workplace






FDFSFPFP2A Operate a pelleting process


RANGE STATEMENT





• The pelleting process typically includes volumetricfeeding, steam conditioning of mash, pellet formation andcooling. Some processes also include crumbling andsieving. Processes may include a post pellet mixing stagefor liquid addition

• Pelleting and finishing equipment may include feedscrews and related feed transfer equipment, steamconditioners, expanders, pellet presses, coolers, crumblerolls, screens, sieves, shakers, and post pellet mixers








EVIDENCE GUIDE




• Confirm supply of necessary feed, liquid ingredients andservices

• Conduct pre-start checks. This may involve inspectingequipment condition to identify any signs of wear;selecting appropriate dies and/or roll settings whererequired; setting processing parameters; cancellingisolation or lockouts as required; confirming thatequipment is clean and correctly configured forprocessing requirements; sensors and controls arecorrectly positioned; any scheduled maintenance hasbeen carried out, and that all safety guards are in placeand operational

• Start, operate, monitor and adjust process equipment toachieve required outcomes. This may include monitoringcontrol points and conducting inspections as required ateach stage of the pelleting and pellet finishing process toconfirm process remains within specification

• Monitor supply of feed to and from the pellet formingprocess. Monitor supply of liquid ingredients to postmixing process











Knowledge of: • Purpose and basic principles of each part of the process.This may include volumetric metering, steamconditioning, pellet formation, cooling, crumbling andsieving and post pelleting liquid addition


• Basic operating principles of process control. Thisincludes the relationship between control panels andsystems and the physical equipment


• Quality characteristics and uses of finished pellets• Effect of variation in inputs and/or services on process

performance• Operating requirements and parameters and corrective


• The effect on final product of variation in variables suchas:• pellet diameter to length ratios• oil and fat content• retention time and temperatures for steam conditioning

- includes consequences of temperatures that are toohigh and too low on chemical composition

• retention time and temperature for liquid addition• Typical equipment faults and related causes. This


• Methods used to monitor the pelleting process. This mayinclude inspecting, measuring and testing as required bythe process. It requires awareness of inspection or testpoints (control points) in the process and the relatedprocedures and recording requirements


• Contamination risks related to the pelleting and pelletfinishing process and related controls


• Requirements of different shutdowns as appropriate tothe process and workplace pelleting requirements. Thisincludes emergency and routine shutdowns andprocedures to follow in the event of a power outage












Pre-requisite units









parameters• Production schedule/batch instructions• Specifications, control points and processing parameters• Pelleting, pellet finishing and related equipment and

services• Feed/mass to be pelleted• Sampling schedules and test procedures and equipment



required





FDFTECCCS4A Control food contamination and spoilageUnit Descriptor This unit addresses the systems and procedures in place to prevent

food contamination and spoilage. It includes management of foodsafety and cleaning and sanitation programs. At this level, a personwould be expected to oversee control measures across a productionsite or facility.

Prerequisite Unit(s) FDFCORQFS3A Monitor the implementation of quality and food safetyprograms

Unit Sector Technical


1. Identify legalresponsibilities to producequality, safe food

1.1 Legal and ethical responsibilities to produce safe food areidentified

1.2 Legal, company and customer quality standards forproducts are identified

2. Identify common causesof food poisoning andcontamination

2.1 Food borne pathogens and contamination that can occurin processed food are identified

2.2 Patterns of contamination and spoilage are traced throughprocessing, storage and shelf-life for a given product

2.3 Conditions required for contamination to occur areidentified

2.4 Laboratory results used to detect the presence ofcontamination and/or related conditions are analysed andapplied

3. Manage control measuresto eliminate and/orminimise the risk ofcontamination

3.1 Control measures related to receivals, handling andprocessing, storage and/or transport stages to guaranteefood safety in the workplace are identified

3.2 Control measures to prevent food contamination andspoilage are documented and followed

4. Manage cleaning andsanitation regimes

4.1 The main types of cleaners and sanitizers used in the foodindustry are identified

4.2 Application methods and related materials, labour andequipment requirements are identified

4.3 Appropriate cleaning and sanitation methods are selectedand to suit a given product, processing method and riskfactors

4.4 Inspection and/or test methods are in place to confirm theeffectiveness of the cleaning and sanitation program

4.5 Responsibilities for cleaning and sanitation aredocumented and communicated


FDFTECCCS4A Control food contamination and spoilage


RANGE STATEMENT


Range description • Food borne pathogens and contamination includes thoselisted in the World Health Organisation table on 'Foodborne pathogens and chemicals of public healthimportance'. This is reproduced in a number of foodsafety related documents including 'Food SafetyStandards Costs and Benefits' ANZFA, May 1999

• Food-related legislation relevant to this unit includesrelevant state and federal food safety legislation and theFood Standards Code




EVIDENCE GUIDE


Ability to: • Identify the requirements of legislative responsibilitiesrelating to food production. This includes anunderstanding of food composition; specification of safehandling; processing, storage and transportation methodsas appropriate; and establishment of related programssuch as cleaning and sanitation, personal hygienepractices, training and food traceability and recallprocedures. Identify how these requirements have beenapplied in a production context. This will typically bebased on the food safety program (HACCP) for aproduction process

• Identify related roles and responsibilities forimplementing, maintaining and reviewing the food safetyprogram in a production environment

• Identify the types of pathogenic bacteria, viruses andchemicals that can occur in food. This includes the maintypes of pathogens and contamination that can occur. Fora given product and production method, it includesunderstanding the specific strains that can occur

• Identify the main types and causes of food spoilage thatcan occur. This includes:• bacterial growth• growth of yeasts and moulds• fermentation• enzymic reactions• physical degradation (oxidation)

• Identify the conditions that cause or promote the growthof pathogens and other forms of contamination and foodspoilage

• Identify typical control measures used to preventcontamination from occurring, including microbiological,chemical and physical types of contamination.

• Distinguish between measures to control pathogenicgrowth (critical control measures) and those used toprevent other forms of contamination

• Interpret test results and apply this information in aproduction context. This includes an understanding ofcommon terms including but not limited to:• plate count• culture• colony• bacteriophage• spores• yeasts and moulds• water activity

• For a given product, trace the production process fromreceival of materials/ingredients through to storage andsale to identify the types of contamination that can occurand the controls in place to prevent or minimise the




likelihood of contamination occurring. Where a foodsafety plan has been developed, compare the outcomesof this process with the provisions of the food safety plan

• Review workplace information to ensure that criticalcontrol measures and procedures are documented in aform appropriate to meet company and legalrequirements and that quality control measures andprocedures are documented to meet company andcustomer requirements. Documentation includes action tobe followed in the event of an incident or emergency andshould be reflected in food safety plans and operatingprocedures

• Identify the cleaning and sanitationrequirements/standards appropriate for a food processingenvironment. This includes an understanding of the legalresponsibilities to maintain food production facilities in aclean and sanitary condition, the difference between asurface that appears clean and one that ismicrobiologically described as clean, and use of termssuch as sterile and commercially sterile

• Identify the types of cleaners, sanitizers and combinedcleaning/sanitation agents used in the food industry andrelated application methods. Identification can be basedon active ingredients and includes but is not limited toalkaline and acid-based detergents, steam/hotwater-based methods of sanitation, bleach-basedsanitizers, QUATs ( quaternary ammonium compounds),alcohol-based sanitizers, use of UV light, gammaradiation and combined cleaners/sanitizers

• Evaluate the appropriateness of available methods to agiven production process/product type. This requires anunderstanding of criteria for evaluation to take account ofthe effectiveness of the method in controllingcontamination risk, equipment requirements, cost andother criteria as identified by the workplace. It alsorequires an understanding of issues of compatibility ofcleaning agents with materials used inequipment/instrument fabrication

• Develop and/or review a cleaning regime suited to agiven production process. This should specify the nature,frequency and method/s of cleaning and sanitationrequired including removal of residues as appropriate,inspection and/or test methods to confirm effectivenessand allocation of roles and responsibilities. The cleaningregime should balance the need to ensure effectivecleaning and sanitation at the same time as minimisingthe disruption to production

• Identify the possible consequences of failing to follow thecleaning regime

• Develop and/or review procedures to describe themethods, frequency, recording, inspection and testrequirements related to implementation of cleaning andsanitation




• Analyse and interpret test results relating to cleaning andsanitation. This requires a basic understanding oflaboratory procedures used to avoid erroneous resultsincluding practices such as use of negative controls andthe purpose of false positives/false negatives

• For a given type of microbacterial and/or chemicalcontamination, identify likely causes, relevant tests andreview of the effectiveness of existing controls includingcleaning and sanitation measures


Pre-requisite units


• FDFCORQFS3A Monitor the implementation of qualityand food safety programs





• Food safety plan and related information includingoperating procedures, cleaning and sanitationregimes/plans

• Laboratory test results• A given production process and product as the basis for

tracing contamination/spoilage and identifying controlmeasures

• Cleaning and sanitation methods, equipment andprocedures





FDFTECENG4A Apply basic engineering principles to a foodproduction process

Unit Descriptor This unit provides an introduction to process engineering concepts. Itcovers the skills and knowledge required to map production processes,measure outputs (yields, material variances) and apply anunderstanding of the basic principles of systems and equipmentcommonly used in the food processing industry. This includes systemsand equipment used for heat transfer, refrigeration, pumping andevaporation/drying.

Prerequisite Unit(s) FDFZPRCI2A Operate a process control interfaceFDFTECNUM4A Describe and analyse data using mathematicalprinciples



1. Map a production process 1.1 The scope of a production process to be mapped isidentified

1.2 Appropriate process mapping symbols are selected andused

1.3 A map is developed that identifies the relationship of eachstep in the process

2. Calculate yields andefficiencies of aproduction process

2.1 Inputs to and outputs of a production processing systemare identified

2.2 Information required to monitor performance of aproduction process is collected

2.3 Calculate yields, efficiencies and material variances

3. Apply principles of fluidflow to a productionprocess

3.1 Fluid properties that affect flow are identified3.2 Components and related equipment used in the pumping

system are identified3.3 Features of the system design that affect performance of

the pumping system are identified3.4 The effect of pumping on the fluid properties is identified3.5 The operating capacity of pumping systems used in the

production process is established3.6 Procedures for the safe use of pumping equipment are

reviewed and/or established

4. Apply principles of heattransfer to a productionprocess

4.1 Types of heat transfer are identified4.2 Methods and related equipment used to transfer heat are

identified4.3 Types of heat transfer media are identified4.4 Operating principles of cooling, chilling and freezing

processes are identified4.5 The effect of heat transfer on product/material properties

is identified4.6 The operating capacity of heat transfer equipment used in

the production process is established4.7 Procedures for the safe use of heat transfer equipment

are reviewed and/or established


FDFTECENG4A Apply basic engineering principles to a food production process


5. Apply principles ofevaporation to aproduction process

5.1 Methods and related equipment used for evaporation areidentified

5.2 The effect of evaporation on product/material properties isidentified

5.3 Tests used to determine the concentration of a liquid areidentified

5.4 The operating capacity of evaporation equipment used inthe production process is established

5.5 Procedures for the safe use of evaporation equipment arereviewed and/or established

6. Apply principles of dryingto a production process

6.1 Methods and related equipment used for drying areidentified

6.2 The effect of drying on product/material properties isidentified

6.3 Tests used to determine moisture content of materialsand/or product are identified

6.4 The operating capacity of drying equipment used in theproduction process is established

6.5 Procedures for the safe use of drying equipment arereviewed and/or established

7. Apply principles ofprocess control tomanagement ofproduction processes

7.1 Locate sensors and instrumentation providing inputinformation to the control system

7.2 Identify consequences of a system malfunction

RANGE STATEMENT


Range description • Uses of processing equipment and related workprocesses are consistent with company policies andprocedures, regulatory and licensing requirements,legislative requirements, and industrial awards andagreements and takes account of OHS andenvironmental impact

• Calculation of yields, efficiencies and material variancesmay involve use of software programs and systems suchas SAP or may involve application of a relevant formula




EVIDENCE GUIDE


Ability to: • Establish and apply process mapping protocols andsymbols used in the workplace to describe a productionprocess

• Identify the inputs to a production process and theoutputs of a production process

• Identify the data required to calculate yields, efficienciesand material variances. Locate sources of this informationin the workplace. This may involve printing reports frominformation management systems

• Calculate yields, efficiencies and material variances. Thismay involve the use of software or application of aformula

• Identify properties of fluids that affect fluid flow. Thisincludes viscosity, temperature and size, and distributionof particulates

• Identify types of pumping equipment appropriate fordifferent types of liquids

• Identify the basic operating features and components ofpumps commonly used and typical applications. Thisincludes but is not limited to:• rotodynamic (centrifugal) pumps• positive displacement pumps. This includes

reciprocating piston pumps, rotary pumps includinggear and lobe pumps, screw pumps, eccentric rotorpumps including progressive cavity or Mono pumpsand flexible vane pumps

• Identify related components of the pumping systemincluding valves, taps and pipework. It may also includean understanding of Australian Standard and workplaceprotocols for indicating materials carried by pipework

• Identify tests or measures taken to monitor operation ofpumps and related performance information. Apply thisinformation to describe pump system capacity in aproduction process

• Identify features in the pumping system design thataffects pumping efficiencies including length of pipework,number and placement of valves and fittings, height ofinlet and discharge points, internal surface and diameterof the pipe. It also requires an understanding of thefollowing terms:• pressure and pressure drop• velocity• head

• Identify possible effects of pumping on liquid properties• Identify operational and safety features of pumps used in

a production process. This includes an understanding ofinspections required to identify signs of faultyperformance and/or wear

• Review and/or establish procedures to define safe pump




operation and maintenance• Identify heat transfer methods and types of equipment

commonly used in the food industry This includes but isnot limited to:• retorts• jacketed vessels/kettles• heat exchangers - including plate, tubular and scraped

surface• cooling tunnels• refrigeration circuits• chillers• freezers

• For each heat transfer method, identify typicalapplications in the food industry and the heat transfermedium used

• Identify the effects of heat transfer on properties ofmaterials/products. This includes an understanding ofpossible consequences where the heat transfer processis not operated within specified parameters

• Distinguish between conduction, convection and radiationin the application of heat

• Identify the properties of heat and steam. This includesan understanding of the terms latent heat, saturated andsupersaturated steam

• Identify the heat transfer requirements and equipmentused in a production process. This includes mapping thestages and equipment used in a heat transfer processincluding holding stages

• Identify tests or measures taken to monitor performanceof heat transfer equipment and related expression ofperformance information. Apply this information todescribe heat transfer process capacity in a productionprocess

• Identify operational and safety features of heat transferequipment used in a production process. This includes anunderstanding of inspections required to identify signs offaulty performance and/or wear

• Review and/or establish procedures to define safeoperation and maintenance of heat transfer processesand equipment used in a production process

• Identify the effects of evaporation on product. Thisincludes but is not limited to:• physical property changes such as crystallisation,

increased solids/viscosity• intensification of flavour and concentration of acids• changes in microbiological characteristics due to

application of heat and reduction of moisture/wateractivity

• Identify the equipment components of an evaporationprocess. This includes but is not limited to:• heat transfer surface (rising film, falling film, forced

circulation and plate)• vapour separator




• vapour condenser• vacuum unit

• Map the stages and equipment used in an evaporationprocess

• Identify tests or measures taken to monitor performanceof an evaporation process and related expression ofperformance information. Apply this information todescribe evaporation process capacity in a productionprocess

• Identify tests carried out to determine material/productsolids and related terms. Common test methods includeBaume, refractive index, and brix

• For a given volume of product, a target total solids level,and a given evaporation process, identify the processingparameters, time required to achieve the target result andsteam required

• Identify operational and safety features of evaporationequipment used in a production process. This includes anunderstanding of inspections required to identify signs offaulty performance and/or wear

• Review and/or establish procedures to define safeoperation and maintenance of evaporation processes andequipment used in a production process

• Identify the effects of drying on product. This includes butis not limited to:• changes that occur at each stage of the drying process• reduction in weight and bulk• changes in microbiological characteristics due to

application of heat and reduction of moisture/wateractivity

• Identify the equipment components of a drying process.This includes but is not limited to:• hot air drying - fluidised bed driers, spray driers, belt

trough driers, and air lift driers• freeze drying (vacuum)

• Map the stages and equipment used in a drying process• Identify tests or measures taken to monitor performance

of a drying process and related expression ofperformance information. Apply this information todescribe drying process capacity in a production process

• Identify tests carried out to determine process outcomeson material/product

• For a given volume and type of product, a target moisturelevel, and a given drying process, identify the processingparameters, time and energy required to achieve thetarget result

• Identify operational and safety features of dryingequipment used in a production process. This includes anunderstanding of inspections required to identify signs offaulty performance and/or wear

• Review and/or establish procedures to define safeoperation and maintenance of drying processes andequipment used in a production process




• Identify the main types of sensors used in foodprocessing to provide input data to control systems andhow these sensors operate

• Identify the location and operation of sensors and relateddata input devices to a control system on equipment usedin a production process

• For a given production process, identify the criticality ofsystem control and consequences of a systemmalfunction or power outage

• Develop and/or review procedures to be followed in theevent of a system malfunction or power outage


Pre-requisite units


• FDFTECNUM4A Describe and analyse data usingmathematical principles

• FDFZPRCI2A Operate a process control interface

Co-assessment of relatedunits




• Production process and related equipment,manufacturers' advice and operating procedures

• Methods and related software systems as required forcollecting data and calculating yields, efficiencies andmaterial variances appropriate to production environment

• Tests used to report relevant product/process informationand recorded results





FDFTECENV4A Manage the implementation of environmentalmanagement policies and procedures in theworkplace

Unit Descriptor This unit covers the skills and knowledge required to provide aleadership role in supporting day-to-day implementation ofenvironmental management policies and procedures in one or morework areas. This unit applies to those with formal responsibility forothers.

This unit is based on and equivalent to BSBCMN413A Implement andmonitor environmental policies.



1. Ensure others in the workarea are able toimplement environmentalwork practices

1.1 Hazard control equipment and personal protective clothingand equipment appropriate to work requirements andavailable and functional

1.2 Systems are implemented to confirm that others in thework area are aware of their responsibilities for supportingenvironmental policies, procedures and programs

1.3 Environmental hazards and control measures relating towork responsibilities can be identified by those in the workarea

1.4 Mentoring and coaching are available to supportindividuals/groups to implement procedures to supportenvironmental management

1.5 Training needs are identified and addressed within level ofresponsibility

2. Monitor observance ofwork procedures tosupport environmentalmanagement

2.1 Work procedures to support environmental managementare clearly defined, documented and followed

2.2 Environmental hazards in the work area are identified,measured and reported according to workplaceprocedures

2.3 Deviation from identified procedures is identified, reportedand addressed within level of responsibility

2.4 Personal behaviour is consistent with workplace policiesand procedures

2.5 Actual and potential non-compliance is identified, rectifiedand reported within level of responsibility

2.6 Environmental information is recorded to meet workplacereporting requirements

2.7 Housekeeping standards in the work area are maintained


FDFTECENV4A Manage the implementation of environmental management policies and procedures in the workplace


3. Implement emergencyprocedures to respond tohazardous events

3.1 Systems are implemented to confirm that others in theworkplace are aware of their role and the requiredresponse in case of a hazardous event

3.2 Workplace procedures for dealing with hazardous eventsare promptly implemented as required

3.3 Hazardous events are investigated to identify cause3.4 Control measures to prevent recurrence and minimise

risks of hazardous events are implemented

4. Maintain and improveenvironmentalmanagement in the workarea

4.1 Work activities and procedures are planned to ensurecompliance with workplace policies and legalenvironmental management requirements

4.2 Procedures are developed and/or revised to supporteffective control of environmental hazards

4.3 Risk assessments are conducted and appropriate controlmeasures are identified and implemented according toworkplace risk management procedures

4.4 Systems are implemented to confirm that control methodsare effective and appropriate

4.5 Inadequacies in control measures are identified andreported according to workplace reporting requirements

4.6 Data recorded on environmental performance is reviewedto identify opportunities for improving environmentalperformance

5. Implement participativearrangements

5.1 The work group is consulted and advised of environmentalresponsibilities and procedures relevant to work role

5.2 Outcomes of consultation on environmental issues arereported back to the work group promptly

5.3 Matters raised relating to environmental management arepromptly resolved or referred to the appropriate personnel




RANGE STATEMENT


Range description • At this level the supervisor/manager is responsible formonitoring and managing implementation of work andrelated environmental management policies, proceduresand programs across one or more work areas. Thistypically involves overseeing implementation by a largergroup and/or across more diverse operations than wouldapply to a person at AQF 3

• Work is carried out in accordance with companyprocedures, regulatory and licensing requirements,State/Territory/Commonwealth legislative requirements,site licences and industrial awards and agreements. Thisincludes agreements or licences issued by resourcemanagement authorities

• Company procedures may include job-related SOPs andenvironmental-specific procedures. Examples ofenvironmental procedures include emergency response,response to specific hazards, incident investigation, riskassessment and reporting arrangements

• When applied to the pharmaceutical industry, relevantGMP codes apply in place of the Food Standards Codeand reference to food safety is replaced by GMP

• Work responsibilities include responsibility for modellingappropriate environmental policies and procedures andmay include formal or informal responsibility for providinga support role to others in the work area

• Where measures for controlling environmental hazardsinvolve work conditions covered by National OccupationalHealth and Safety Commission and/or state health andsafety authorities, the assessment criteria and methodsprescribed by these authorities must also be met

• Environmental management concepts include controllingenvironmental hazards and risks and responsibleresource management

• An environmental hazard is any activity, product orservice which has the potential to affect the environment.This may also be referred to as an environmental aspect

• An environmental risk is the likelihood that the hazard cancause harm to the environment

• A control measure is a method or procedure used toprevent or minimise environmental risks

• Consultation would typically involve discussing issues,considering and responding to feedback on issuesincluding but not limited to identification of hazards,assessment of risk level, hazard control options,investigation of non-conformance, and developmentand/or review of work procedures to supportenvironmental management

• Work responsibilities include formal responsibility for




providing a support role to others in the work area and forcounselling others on unacceptable work performance

• The manager at this level is expected to be able to initiateinvestigations and risk assessments and assess theeffectiveness of control measures

• The manager may not have direct responsibility foroverseeing the training/development of team members.At a minimum they must identify development needs ofothers in the work area and refer this information to therelevant personnel. Training may include inductiontraining, specific hazard management training, use ofspecific equipment, emergency response training andtraining as part of developing broader job-relatedcompetencies

• Responsibilities at this level may include facilitatingconsultation processes within level of responsibility

• Record keeping complies with legal and workplaceenvironmental management program requirements




EVIDENCE GUIDE


Ability to: • Communicate information about environmentalmanagement and related procedures to others in thework area. This involves selection of appropriate methodsfor communicating information across a work area andfacilitation of structured meetings and information forums

• Provide access to and maintain current environmentalmanagement information in the work area. This typicallyincludes policies and Standard Operating Proceduresand/or environmental procedures

• Model work policies and procedures to supportenvironmental management in own work

• Ensure that safe work procedures are implemented byothers in the work area

• Identify environmental hazards and controls relevant towork processes and practices in the work area

• Monitor responsible resource utilisation in the work area,consistent with company policies

• Implement systems for identification of environmentalhazards and controls relevant to work processes andpractices in the work area such as audits, workplaceinspections, and review of environmental records

• Support others to follow environmental managementprocedures. This involves ensuring that all personnel inthe work area receive the information and trainingrequired, that they have met the necessarycompetency/regulatory and licensing requirements tocarry out their work responsibilities, that the appropriaterisk control strategies and equipment are in place andthey are equipped with the relevant personal protectiveclothing and equipment. This may apply to both companyemployees and subcontractors

• Identify, report and/or address environmentalmanagement training and development needs of others inthe work area

• Counsel others on non-compliance in accordance withworkplace procedures

• Implement systems to confirm that work and wastecollection, treatment, recycling or disposal is conducted tomeet environmental obligations

• Identify, report and/or address environmentalmanagement training and development needs of others inthe work area

• Lead investigations of non-compliance, risk assessmentsand incident investigations

• Lead consultation processes to improve environmentalmanagement in the workplace. Processes must provideopportunities for all employees to participate

• Respond to environmental management hazardidentification and incidents in an appropriate and timely




way• Review practice and procedures to implement

recommendations arising from risk assessments and/orimprovement proposals within level of responsibility

• Review environmental records generated in the work areafor accuracy, completeness and timeliness

• Use environmental data to evaluate effectiveness of theenvironmental management system and identify areas forimprovement

• Plan implementation of improvements according toworkplace procedures

• Predict impact of planned changes on related work areasand consult as appropriate

• Design and plan changes to equipment and process totake account of environmental impact

• Ensure that appropriate and timely action is taken inresponse to emergencies




Knowledge of: • Responsibilities of self and employer to manageenvironmental issues on site. This includes company andpersonal duty of care. It also includes an awareness ofthe company's role as a good corporate citizen

• Legal responsibilities. This includes awareness of anylicences or agreements in place with resourcemanagement authorities and the purpose of thesearrangements

• Workplace approach to managing environmental issues.This includes awareness of the relationship betweenenvironmental management and related policies, the roleof operating and environmental procedures, hazard andincident reporting and investigation processes, trainingarrangements, structure and role of consultativeprocesses, sources of information on environmentalissues, personnel responsible for environmental issues,and may include the role of internal and external auditorsas appropriate

• Elements of an effective environmental managementsystem including the role of maintenance, purchasing,contractors, training, consultation, and planning

• Principles of environmental management includingconservation of energy and resources and control ofenvironmental hazards and risks

• Principles of risk management including hazardidentification, risk assessment and risk control accordingto hierarchy of control

• Environmental hazards and control measures typicallyused in the industry. This includes an awareness ofindustry standards, practices and external sources oftechnical information

• Safety hazards related to environmental managementprocedures

• Work activities that support environmental managementincluding any covered by special training requirements

• Consultation mechanisms and responsibilities• Protocols for consulting and communicating with

authorities and with the public on environmental issues• Appropriate communication skills and techniques to

convey information on environmental issues to others.This includes the ability to present information in suitableformats for given audiences, facilitate structured meetingsand convene information forums as appropriate withinconsultation arrangements and responsibilities

• Emergency response system, procedures and personnel• Auditing arrangements, roles and responsibilities as they

relate to the work area. This includes an understanding ofinternal and external audit processes

• Documentation system and procedures. This includesrecord keeping to meet both company and legalrequirements, procedures for developing and/or reviewingworkplace procedures and document control systemsused in the workplace




• Current practices used to evaluate environmentalperformance data. This includes an awareness of OHSrecord keeping responsibilities and methods of analysis


Pre-requisite units

There are no pre-requisites for this unit.



• FDFOPTTG3A Lead work teams and groups• PMBOHS204B Apply emergency/incident procedures• FDFOPTPIP3A Participate in improvement processes• BSBCMN405A Analyse and present research information



• Environmental legislation and relevant site agreements• Environmental policies and procedures• Work procedures, including environmental operating

requirements and risk control methods• Work area or tasks in which environmental policies and

procedures are to be monitored• Site plans including relevant advice on drainage system

and power sources• Standard operating procedures and related advice on

specific environmental procedures• Advice on environmental hazards and control procedures

relevant work area• Personal protective clothing and equipment as required• Emergency and/or evacuation procedures for the

potential range of hazards• Consultative forums relating to environmental issues• Storage areas for hazardous goods as required• Waste collection, treatment, recycling and/or disposal

methods• Environmental reporting systems and requirements





FDFTECFAD4A Apply an understanding of food additivesUnit Descriptor This unit covers the knowledge required to recognise the characteristics

and functions of food additives, preservatives, colours and flavoursused in food products.

This unit is designed to provide an overview of food additives. It is notdesigned to meet the competency requirements of the person whospecifies additives, preservatives, colours or flavours to be used infood.



1. Identify additives used infood

1.1 Types of food additives and common additives used infood products are identified

1.2 Functions of food additives are identified1.3 Legal requirements relating to use of food additives are

identified1.4 Legal and quality consequences of incorrect additive

addition are identified

2. Manage use of additivesin a production process

2.1 Additives used in product range produced in theproduction process are identified

2.2 Methods of addition are suited to food additive andproduction requirements

2.3 Procedures for safe handling and addition of foodadditives are reviewed and/or established

RANGE STATEMENT


Range description • Handling of food additives, preservatives, colours andflavours and related work processes are consistent withcompany policies and procedures, regulatory andlicensing requirements, legislative requirements, andindustrial awards and agreements and takes account ofOHS and environmental impact

• Analysis of the properties of food additives may be doneby a specialist


FDFTECFAD4A Apply an understanding of food additives


EVIDENCE GUIDE


Ability to: • Identify common food additives and group them byfunction. Groupings include but are not limited to:• preservatives• anti-oxidants• acidulants• organoleptic and nutritional modification agents• colours and flavours - includes synthetic and natural;

oil and water soluble and lakes (dispersion in oil -applying to colours only)

• technological aids• For each main grouping, identify common types of

additives used in the food industry• Identify the functions of food additives commonly used in

food. This includes but is not limited to the functions of:• texture modifying agents• organoleptic and nutritional modifying agents. This

includes flavours, colours, flavour enhancers,sugar-free sweeteners, minerals, vitamins and foodacids

• shelf-life enhancing agents. This includespreservatives, anti-oxidants and food acids

• technological aids. This includes humectants,enzymes, propellants, flour treatment, caking agents,and bleaching agents

• Identify additives, colours and flavours used in productrange produced in the workplace. For each type, identify:• coding system used to describe food additives, colours

and flavours• legal requirements relating to additives used as

established by the Food Standards Code• function in the food product• typical quantities used and related units of

measurement• preparation requirements. This may require an

understanding of forming and breaking emulsions, andpreparation of solutions

• addition systems and related equipment requirements• health and safety issues related to handling of

additives• process recording requirements• consequences of incorrect additive addition. This

includes an understanding of the Food StandardsCode as it relates to food additives used in a givenproduct range. It also covers an understanding of thequality and food safety hazards of incorrect addition

• Review and/or establish procedures to describe storage,handling and processing conditions that affect thecharacteristics of colours and flavours. This includes butis not limited to:




• changes in pH• temperature change• exposure to light• exposure to humidity• packaging materials

• Review and/or establish procedures to describe themethod of preparation and addition of additives to foodproducts produced in the workplace

• Given examples of incorrect addition of food additivesthat could occur in the production process, determineappropriate corrective action within company policy andlevel of authority


Pre-requisite units






• Product specifications including advice on additives• Food Standards Code• Product range and related production processes• Workplace information recording systems, requirements

and procedures





FDFTECLEG4A Apply an understanding of legalrequirements in food production

Unit Descriptor This unit covers an understanding of legal requirements. It does notinclude requirements related to environmental management,occupational health and safety and food safety. These areas arecovered by other units.

The intent of this unit is to introduce the range of legal requirementsapplying to food processing activities and facilities. The person whoundertakes this unit may not be directly responsible for designingpremises, equipment or procedures to comply with legislation butshould be aware of the existence of legislation, its intent and thearrangements in place to ensure compliance.



1. Manage productionsystems to meetlegislative requirementsrelating to product andprocessing

1.1 Identify relevant legislation and regulations that apply foodproduction, packaging and labelling

1.2 Identify the purpose and intent of relevant legislation1.3 Identify the roles and responsibilities of authorities

responsible for administering legislation1.4 Establish and/or review procedures to support compliance

with legal requirements

2. Manage productionfacilities to meetlegislative requirementsrelating to food premises,equipment design andstorage facilities

2.1 Identify relevant legislation and regulations that apply foodpremises, storage facilities and equipment

2.2 Identify the purpose and intent of relevant legislation2.3 Identify the roles and responsibilities of authorities

responsible for administering legislation2.4 Establish and/or review procedures to support compliance

with legal requirements

RANGE STATEMENT


Range description • Legislation to be covered by this unit includes:• Food Standards Code• Australian Standards• Food Safety legislation (including provisions covering the

design of food premises and equipment)• Customs and excise legislation (for alcohol-based

ingredients/materials)• Dangerous goods legislation• Import and export legislation• Additional legislation as appropriate to product, process

and market


FDFTECLEG4A Apply an understanding of legal requirements in food production


EVIDENCE GUIDE


Ability to: • Identify the legal responsibilities of a food processingcompany. This includes responsibilities relating to:• product content (Food Standards Code)• product packaging and labelling, including use of

nutritional information panels (Food Standards Code)• design requirements of food premises and equipment• requirements of storage facilities used for materials,

ingredients and final product• other requirements as appropriate to the product

and/or market (e.g. import and/or export legislation)• Identify and/or develop specifications and procedures to

ensure that legal responsibilities related to productcontent and packaging are achieved

• Inspect plant design to identify potential hazards thatcould be introduced as a result of equipment design andconfiguration. For example, overhead pipes or equipmentwhere dust could collect and fall into food. Where hazardsare identified, apply the hierarchy of control to identifyopportunities to remove or control the risk

• Identify storage facilities across a production site. Identifythe dangerous goods stored on site and confirm thatstorage of these goods (type and quantity) meets legalrequirements

• Confirm that employees required to handle chemicals anddangerous goods are advised of the associated risks, thatthis information is available in a form appropriate to theaudience and that Material Safety Data Sheets areavailable

• Develop and/or review recording systems to confirmcompliance with legislative requirements and ensure thatemployees responsible for recording information areinformed of these responsibilities

• Establish internal review/audit procedures to confirm thatlegislative responsibilities are met

• Within each area of legislation applying to the activities ofa food processing facility, identify the relevant authorityresponsible for administering the legislation. Identify therights and responsibilities of related officers to access theproduction site





Pre-requisite units



This unit should be assessed together with core units and otherunits of competence relevant to the function or work role. Thismay include

• FDFIMIA4A Manage internal audits



• Workplace processes and procedures• Workplace documentation including specifications and

procedures• Relevant legislation• Communication systems• Workplace information recording systems, requirements

and procedures





FDFTECNUM4A Describe and analyse data usingmathematical principles

Unit Descriptor This unit builds on an understanding of common units of measurement,formulae and mathematical skills related to production activities.

Prerequisite Unit(s) FDFOPTSPC2A Apply principles of statistical process controlUnit Sector Technical


1. Identify common units ofmeasurement anddimensions used todescribe physicalproperties of materialsand food

1.1 Identify SI units of measurement and related unit symbols1.2 Identify and apply common formulae used to measure

characteristics of food1.3 Perform calculations involving fractions and ratios

2. Apply linear algebra toanalyse workplaceinformation

2.1 Given two known values, calculate an unknown value2.2 Apply the principles of transposing values to solve

workplace problems

3. Use graphs to analyseworkplace information

3.1 Identify data analysis and presentation requirements3.2 Generate graphs to analyse and display workplace

information3.3 Construct a process control chart

RANGE STATEMENT


Range description • Common measurements include but are not limited todensity, specific gravity, volume, weight, mass, andspeed

• Graphs to be covered in this unit include but are notlimited to Statistical Process Control (SPC) charts and x-ycharts


FDFTECNUM4A Describe and analyse data using mathematical principles


EVIDENCE GUIDE


Ability to: • Identify the fundamental units (SI) of measurement -metres, kilograms and seconds

• Identify common derived units/measurements, relatedformulae and their application in a food processingcontext. Common measurements include but are notlimited to:• density, specific gravity• viscosity• temperature• volume, weight and mass• velocity• other measures as appropriate to a production process

• Apply relevant formulae to measure physicalcharacteristics of food products and/or processes

• Select production calculation requirements, such as theadjustment of a recipe formulation, to:• select required formulae• express the problem as an equation• identify the known and unknown values• manipulate equations by transposing values as

required• convert units into compatible formats (i.e. SI units,

multiples and sub-multiples)• calculate of percentages and ratios• conduct the calculation to obtain a solution• record the result in the appropriate units and level of

detail• Identify graphs commonly used in the workplace and

relevance to displaying workplace information• Construct charts to analyse and illustrate workplace

information. This may include use of relevant software• Calculate standard deviation for a given data set• Apply an understanding of standard deviation to

determine capability of a process• Identify the target (mean value) for the process• Identify upper and lower control limits to provide for 98%

of units to fall within the limits





Pre-requisite units

The pre-requisite for this unit is:



This unit should be assessed together with core units and otherunits of competence relevant to the function or work role. Thismay include

• FDFIMEPC4A Establish process capability



• Workplace processes and procedures• Workplace documentation including conversion charts,

sampling plan and control chart formats, related datacollection methods such as log sheets, and relevantformulae to be applied to a production process





FDFTECPAK4A Apply principles of food packagingUnit Descriptor This unit covers the knowledge required to oversee packaging

operations and assess the nature and likely causes of packagingproblems. It covers a range of packaging technologies and isappropriate for a senior operator or manager responsible for overseeingpackaging processes. The unit includes a basic understanding of theprinciples of modified atmosphere packaging processes.

This unit is not designed to meet the competency requirements of theperson responsible for determining packaging specifications, nor does itcover food packaging and labelling legislation. Where this is arequirement, refer to FDFTECLEG4A Apply an understanding of legalrequirements in food production.



1. Identify characteristics ofpackaging suitable for usewith food products

1.1 Packaging materials suitable for food application areidentified

1.2 Packaging interactions with food products are identified1.3 Environmental and handling features of packaging

materials are identified1.4 Customer and legal requirements of packaging are

identified1.5 Packaging material characteristics meet the needs of the

food to be packaged

2. Apply packagingknowledge in a productionenvironment

2.1 Properties of packaging materials used in a packagingprocess are identified

2.2 Costs of packaging materials are identified2.3 Procedures for safe operation of the packaging process

are established and/or reviewed2.4 Out-of-specification packaging outcomes are analysed to

identify probable cause2.5 Opportunities for improvement are identified and

investigated within level of technical responsibility2.6 Proposals for improvement are developed and

implemented within level of authority and according tocompany procedures


FDFTECPAK4A Apply principles of food packaging


RANGE STATEMENT


Range description • Product packaging and related work processes areconsistent with company policies and procedures,regulatory and licensing requirements, legislativerequirements, and industrial awards and agreements andtakes account of OHS and environmental impact

• Packaging processes and technologies include activepackaging materials, vacuum packing, gas flushing orsparging and Modified Atmosphere Packaging (MAP)

• Follow-up action in response to out-of-specificationresults occurs in consultation with the relevantquality/technical expert responsible for packagingspecifications




EVIDENCE GUIDE


Ability to: • Identify properties of packaging materials as specified inpackaging specifications for product handled

• Identify the quality assurance systems in place to ensurethat the packaged product meets customer and legalrequirements

• Identify factors that affect shelf-life of the packagedproduct and the features of packaging design thatpreserve the product

• Identify problems that occur in the packaging process andinvestigate likely causes

• Determine appropriate corrective action to preventpackaging non-conformance

• Identify packaging materials suitable for use with foodproducts. This includes plastics, paper-based materials,glass and metal-based materials

• Describe the purpose of packaging and an understandingof the properties of packaging materials designed toprotect product and extend shelf-life. This includes therole of packaging to provide:• protection of product from contamination - microbial,

pest infestation, and physical damage• barriers - atmospheric, moisture, flavour and light• package sealability and seal integrity• easy-to-open access to the product• information to the consumer about the product• market appeal

• Identify legal requirements relating to packaged productincluding Food Standards Code requirements and otherlegislation relevant to the product

• Identify pathogens and spoilage that can occur inpackaged food and the conditions required for these tooccur. This includes an awareness of features intrinsic tothe food type. These factors will differ according to foodtype. Common factors include pH, Aw, nutrient content,presence of microbiological compounds, respiration rate(fresh fruit and vegetables) and biological structure. Italso includes extrinsic factors such as processingmethod, temperature, water loss/humidity, maturity(applies to maturity of fruit and vegetables whenharvested), handling, cleaning, sanitation and personalhygiene practices and gaseous composition of thestorage atmosphere. Food spoilage indicators includemicrobial contamination, enzymic browning and sensorydegradation of characteristics such as flavour, aroma,colour and texture

• Describe the features of packaging material requirementsof products handled in the workplace. This includes anunderstanding of materials such as coated packagingproducts, active/interactive packaging films. It also




includes an awareness of the characteristics of producthandled and its behaviour when packaged over theshelf-life of the product. For example, reactions that occurwhen canning some types of vegetables requiringappropriately coated cans; respiration that is ongoingafter fresh fruit and vegetables are packaged requiringgas permeable packaging materials; and the effect ofhigh moisture and high fat content products on thepackaging process where MAP packaging processes areused

• Identify factors that influence selection of packagingmaterials including market appeal, suitability for use withthe food product/s to be packaged, compatibility withpackaging technology, cost, environmental features,consumer safety/tamper evidence

• Identify packaging methods and technologies designed toextend shelf-life. This includes active packagingmaterials, vacuum packing, gas flushing or sparging andModified Atmosphere Packaging (MAP)

• Describe the significance of factors such as moisture andtemperature in promoting/preventing product spoilage

• Identify typical problems that occur in the packagingprocess, and outline likely causes and appropriateresponse options within level of responsibility. WhereMAP is used, this includes pack collapse and may includefogging (relevant to fresh fruit and vegetables)

• Identify relevant sources of technical expertise andrelated authority levels to address packaging issues

May include:

• For MAP packaging processes - describe the effect ofgas composition on the packaged product. This includesan understanding of the role of the most commonly usedgases in food packaging including carbon dioxide, oxygenand nitrogen and the reaction between gases, thepackaged product and the packaging material


Pre-requisite units









• Packaging specifications• Product, packaging components and consumables• Packaging process equipment• Relevant standard operating procedures• Communication systems• Workplace information recording systems, requirements

and procedures





FDFTECPPR4A Participate in product recallsUnit Descriptor This unit covers the knowledge required to identify circumstances that

could warrant a product recall and to initiate and/or participate in recallprocesses within level of authority. This unit can apply where a personhas primary responsibility for initiating a product recall or where theyare required to participate in the recall decision and related process aspart of a team.

Prerequisite Unit(s) FDFCORQFS3A Monitor the implementation of quality and food safetyprograms



1. Identify product recallsituations

1.1 Circumstances that could result in a product recall areidentified

1.2 Appropriate controls are in place to manage risks1.3 Criteria used to initiate a product recall are identified1.4 Legal responsibilities and requirements of a recall

program are identified

2. Participate in a productrecall

2.1 The components of the product recall system in theworkplace are identified

2.2 Workplace systems are used to trace ingredients,materials and batch information

2.3 Product recall procedures are implemented within level ofresponsibility

2.4 Procedures to define roles and levels of authority in theevent of a product recall are established/reviewed

3. Review processes tominimise the risk ofrecurrence

3.1 The cause/s of the product recalls are investigated3.2 Purchasing arrangements and in-house procedures are

established or reviewed to minimise the risk of recurrence3.3 Consultative mechanisms are established and/or reviewed

to support continuous improvement and communicateinformation on product recalls

RANGE STATEMENT


Range description • Product recalls and related work processes are consistentwith company policies and procedures, regulatory andlicensing requirements, legislative requirements, andindustrial awards and agreements and takes account ofOHS and environmental impact

• Product recalls occur in the context of an establishedrecall procedure


FDFTECPPR4A Participate in product recalls


EVIDENCE GUIDE


Ability to: • Identify relevant workplace information. This includes thecompany's food safety plan and vendor assurancearrangements

• Identify the risks that could result in the need to initiate aproduct recall and the control measures in place toprevent incidents occurring

• Identify legal and company requirements of the productrecall system. This includes a basic understanding of theprovisions of food safety legislation and related companysystem and criteria for determining when a recall isrequired

• For a given range of circumstances that could result inthe need for a product recall, outline appropriateresponsive action within company policy and procedures

• Identify and/or develop the components of the recallsystem to meet company and legal requirements. Thisincludes information recording systems to supporttraceability; identification of personnel responsible forassessing information and determining appropriateaction; and procedures that define roles and levels ofresponsibility

• Identify the social, financial and legal consequences offailing to initiate a recall or for delaying the decision

• Identify and/or develop procedures for the investigation ofcauses and review of arrangements and procedures inthe event of an incident. This could involve reviewingresponses to previous incidents to assess effectivenessand/or developing recommendations on appropriateprocedures

• Identify and/or develop the appropriate communicationsystems and channels for consulting with people affectedby the recall procedure and communicating informationon improvements to be implemented


Pre-requisite units

The pre-requisite for this unit is:

• FDFCORQFS3A Monitor the implementation of qualityand food safety programs and procedures








• Company food safety program and related informationrelevant to product recall. This can include contractualarrangements with suppliers, product specifications andprocess parameters, and recall procedures

• Legislation relating to product recall including relevantfood safety legislation

• Workplace information recording systems, requirementsand procedures





FDFTECPSC4A Identify the physical and chemical propertiesof materials, food and related products

Unit Descriptor This unit covers an understanding of common physical phenomena andbasic chemistry relevant to food processing. It requires application ofthis knowledge to a production environment.



1. Apply understanding ofcommon physicalphenomena in the foodindustry

1.1 An understanding of common physical phenomena isapplied to explain relevant changes that occur toingredients and product through the production process

1.2 Information on the changes that occur is communicated toothers in appropriate formats

2. Apply an understanding ofthe physical states ofmatter

2.1 The three states of matter and the atomic changes thatoccur at each phase are identified

2.2 The behaviour of each type of matter and its relationshipto the production process is described

2.3 The relationship between pressure and temperature inphase transition is identified

3. Apply an understanding ofcommon food scienceprinciples to a productionprocess

3.1 The significance of pH for processing, food safety andcleaning applications is identified

3.2 The reactions and properties of carbohydrates, proteinsand fats can be tracked through a given process

3.3 The properties of common emulsions, suspensions andsolutions can be described

3.4 Common chemical reactions that occur, factors required tocause a reaction and the effect of reactions can beidentified

3.5 Safe work procedures for processes requiring handling ofchemicals and/or involving chemical reactions arereviewed and/or established

4. Communicate andinterpret technicalinformation

4.1 Appropriate technical terms are used to communicateinformation on properties of food and materials commonlyused in the food industry

4.2 Test results and reporting formats to communicateinformation on composition, properties and reactions areinterpreted and applied


FDFTECPSC4A Identify the physical and chemical properties of materials, food and related products


RANGE STATEMENT


Range description • Handling and processing of product and materials isconsistent with company standards and requirements,legislative requirements, codes, industrial awards andagreements

• Identification of molecular structure can be supported byothers and does not necessarily involve use ofmicroscopes in a laboratory




EVIDENCE GUIDE


Ability to: • Identify physical characteristics or phenomena that occurthrough processing. This includes an understanding ofthe following common physical phenomena and shouldinclude any additional phenomena appropriate to theproduction process:• shear and strain• friction• surface tension• pressure• crystallisation• total solids• heat and temperature• relative humidity• work/energy input• viscosity• particle size• melting points, boiling points, freezing points• dew/condensation point• other phenomena as appropriate to product/process

• Identify products and processes where these phenomenacan be observed

• Based on phenomena that can be observed in aproduction process, develop explanatory sketches or flowcharts to communicate how these phenomena affectproduct and process

• Identify tests commonly used to measure thesephenomena and related units of measurement

• Identify molecular changes that occur in states of matter.Apply this to an understanding of common applicationssuch as refrigerant or freeze drying

• For transition phases that apply in a given productionprocess, identify the role of temperature and pressure inthe transition process

• Identify the difference between acids and bases. Classifycommonly used materials, ingredients and indicatorsaccording to pH

• Identify the difference between a strong acid and aconcentrated acid and related units of measurement usedto describe these acids

• Identify typical strengths and concentration levelsrequired for acids and bases commonly used in aproduction process (e.g. cleaning agents). For cleaningagents, identify compatibility with equipment surfacematerials

• Identify the significance of pH for processing, food safetyand cleaning applications

• Identify the basic molecular structures of carbohydrates,proteins and fats

• For a given production process, identify the processing




stages designed to affect the structure of thesecompounds. An example is hydrogenation or denaturingproteins in cooking processes of oil

• Distinguish the difference between solutions, suspensionsand colloidal systems. Colloidal systems include:• emulsions (oil in water/water in oil)• sols (solid-liquid/solid-solid)• gels• foams (gas-liquid/gas-solid)

• Identify typical applications of solutions, suspensions andcolloidal systems in food processing

• Distinguish between dispersed particles and thedispersion medium in colloids

• Identify factors that the affect stability of colloidalsystems. This includes an understanding of stages in aproduction process that can cause a change in thestructure of a colloid

• Identify common chemical reactions that occur in foodprocessing. This includes both spontaneous andcontrolled reactions. Reactions to be covered includeoxidation, enzymic, Maillard and acid-based reactions,and other reactions relevant to a given product type andproduction process

• Identify the role of enzymes in generating biologicalreactions. For example, amylase in bread

• Identify safety hazards and control methods requiredwhen handling chemicals and working with processesthat involve chemical reactions. Review and/or developworkplace procedures to include advice on hazards andrelated instructions on control methods. This includesadvice on action required in the event of an incident suchas a chemical spill or an emergency

• Read and interpret technical information to describe foodproperties and/or reactions. This involves recognition andapplication of appropriate units of measurement andterms


Pre-requisite units






• Production process and related equipment,manufacturers' advice and operating procedures

• Tests used to report relevant product/process informationand recorded results




FDFTECPT5A Manage and evaluate new product trialsUnit Descriptor This unit covers the skills and knowledge required to plan, monitor and

evaluate the trialing of new products in production. This unit applies tothe management of the trial in a production environment. New producttrials typically involve working with a team of area specialists includingproduct development and engineering experts.



1. Establish trial parameters 1.1 New product specifications are defined1.2 Production resource requirements are identified1.3 Project budget and timeline are established1.4 Trial size is appropriate to provide reliable process and

production information

2. Prepare for the newproduct trial

2.1 New product recipe/formula is scaled to suit trialproduction

2.2 Raw materials/ingredients, packaging components andconsumables are identified and confirmed to meet trialrequirements

2.3 Production equipment is identified, available and suitablefor use

2.4 Production personnel are available and have the requiredcompetencies to operate the trial process

2.5 Environmental, food safety and health and safety hazardsof the trial process are identified and appropriate controlmethods determined

2.6 Trial documentation format and procedures are agreed2.7 The trial schedule timeline is established and

barriers/constraints to achieving schedule are identified,monitored and addressed

3. Develop andcommunicate informationon the trial process

3.1 Personnel in related work areas and functions are keptinformed of trial status and progress

3.2 Operators directly participating in the trial are advised oftrial parameters, roles and responsibilities

3.3 Advice on product specifications and operatingprocedures is communicated to the project team

4. Monitor trial progress 4.1 The trial process is monitored to identify actual andpotential barriers to achieving the schedule

4.2 Trial product is produced within specification4.3 Out-of-specification or unacceptable outcomes are

identified and investigated4.4 Unusual or atypical conditions that could affect the

achievement of the schedule are identified4.5 Modifications are made and reported as required

according to trial arrangements


FDFTECPT5A Manage and evaluate new product trials


5. Evaluate trial outcome 5.1 Trial objectives are identified5.2 Resource allocations are assessed against plan5.3 Trial product is assessed against specifications5.4 Production parameters/operating conditions are compared

with scheduled performance5.5 Significant variances are identified and investigated5.6 Improvement opportunities are identified and reported

RANGE STATEMENT


Range description • Trial conditions are consistent with company policies andprocedures, regulatory and licensing requirements,legislative requirements, and industrial awards andagreements and takes account of OHS andenvironmental impact of scheduling arrangements

• Achieving schedule involves meeting productspecifications within given resource allocations andtimelines

• Trial processes typically involve a multi-disciplinary team




EVIDENCE GUIDE


Ability to: • Identify trial objectives and information requirements. Thisincludes clarifying reporting requirements and formats

• Identify trial participants. This includes clarifying roles,responsibilities and levels of authority. Participants mayinclude technical experts, related functions such asplanning, quality assurance and engineering and trialprocess operators

• Establish and maintain effective communicationprocesses to meet the information requirements of allstakeholders

• Assess final product specifications againstrecipe/formulation and processing method to confirmcapability

• Identify production targets and timeframes againstequipment and process capability

• Confirm availability of resources to meet trial schedule.This may include stock levels, equipment availability andcapacity, personnel and storage capacity

• Identify competencies required by trial operators andconfirm availability. This may involve arranging trainingprior to trial

• Confirm that all hazards have been identified andappropriate methods of control are in place to controlenvironmental, food safety and OHS hazards. Controlmethods should be selected consistent with the controlhierarchy

• Establish a detailed trial schedule to manage the process• Ensure that relevant documentation is available in

appropriate formats. This includes productspecifications/recipe formulations, process parametersand operating procedures

• Monitor trial progress against detailed plan to identifyvariances and identify factors that may need to beadjusted to achieve schedule. This typically requiresconsultation with operators and other experts

• Investigate and report on causes of variation and identifyopportunities for improvement. This may involveparticipating in/facilitating problem solving processes

• Collect and evaluate trial information. This may involveparticipating in/facilitating an evaluation team

• Report on trial outcomes and related improvementopportunities to meet reporting requirements of the trialprocess




Knowledge of: • Trial project parameters, constraints and criteria forevaluating outcomes

• Sources of expertise available to support the trial process• Process documentation procedures and requirements to

ensure that the process meets trial outcomes and isconsistent with legislative and company policy objectives.This includes an awareness of relevant legislation

• Factors to be taken into account in planning andmonitoring the trial process. Factors may include but arenot limited to:• product specifications• raw materials/ingredients, packaging components and

consumables• storage capacities• production capacity, configuration and availability• processing parameters• labour requirements and availability• trial production targets/timelines• related OHS, food safety and environmental hazards

and controls• Knowledge of proposed formulations and preferred

processing method to assess constraints andopportunities for improvement. This includes anunderstanding of equipment capability and typicalmaterials usage rates to achieve a given productionoutcome. It may include a knowledge of area experts inrelated roles such as product development andengineering to provide additional expertise

• Systems and procedures for managing OHS,environmental management and food safety through thetrial process consistent with the hierarchy of control

• Project planning, scheduling and monitoring skills. Thismay include the use of relevant software applications

• Investigation and process improvement techniques andprocesses. This includes techniques to collect andevaluate trial data



Pre-requisite units



This unit should be assessed together with core units and otherunits of competence relevant to the function or work role. Inaddition, the following optional unit may be relevant:

• FDFIMEPC4A Establish process capability






• Trial objectives and parameters• New product specifications• Raw materials/ingredients, packaging components and

consumables• Related production equipment• Relevant standard operating procedures• Communication systems• Workplace information recording systems, requirements

and procedures





FDFTECUTE5A Manage utilities and energy for a productionprocess

Unit Descriptor This unit covers the knowledge required to monitor, conserve andcontrol costs of utility and energy supply to a production process.

Responsibility for selecting suppliers and negotiating contracts will differbetween workplaces. The purpose of this unit is to address the skillsand knowledge required to assess requirements, identify suppliers withappropriate capacity, compare costs of supply, monitor usage patternsand recommend improvements to enhance efficiency and reduce cost.The authority to make final decisions on supply may or may not rest atthis level.



1. Assess utility and energyrequirements

1.1 Energy and utility requirements for a given productionfacility are estimated

1.2 Estimates of requirements take account of historicalpatterns of use and forecast production volumes

2. Identify suppliers ofenergy and utilities

2.1 Existing and potential suppliers of energy and utilities areidentified

2.2 Criteria for selection of suppliers is established andapplied

2.3 Suppliers capable of meeting supply criteria are selected2.4 Contingency procedures are reviewed or developed in the

event of failure of supply

3. Monitor energy and utilityuse against budget

3.1 Use of energy and utilities is measured and recorded3.2 Usage patterns are analysed against performance

standards and budget allocations3.3 Cost effective options for balancing the scheduling

requirements for production with containment of energyand utility costs are identified, assessed and implementedwithin level of responsibility

4. Contribute to the moreefficient use of energy andutilities

4.1 Energy and utility losses or sources of waste are identified4.2 Opportunities to improve efficient energy/utility application

are identified, investigated and reported4.3 Consultative mechanisms are established and/or reviewed

to support continuous improvement and communicateinformation on energy and utility efficiency and relatedprocedures


FDFTECUTE5A Manage utilities and energy for a production process


RANGE STATEMENT


Range description • Use of utilities and energy supplies and related workprocesses are consistent with company policies andprocedures, regulatory and licensing requirements,legislative requirements, and industrial awards andagreements and takes account of OHS andenvironmental impact

• Utility and energy for a production facility refers to gas,power, water, steam, air conditioning and other utilities asappropriate to a production facility

• Supply options include internal supply of utilities such assteam and air conditioning as well as external supply




EVIDENCE GUIDE


Ability to: • Map the uses of energy and utilities in production acrossthe production site. This includes identifying patterns ofusage (volume and spread of load)

• Identify the units of measurement used to quantify energyand utilities

• Identify methods used to measure usage rates of energyand utilities. This includes physical measurementinstruments such as meters and measurementtechniques used to track inputs to and outputs of aprocess

• Analyse historical data and sale/production forecasts toproject energy and utility requirements for a givenproduction system over a fixed period

• Identify supplier criteria. This includes but is not limited tocost and capacity

• Identify costs of supply including tariffs and charges. Thisincludes an understanding of peak demand/cost periods

• Identify and evaluate opportunities to spread supplier loadand risk by use of multiple suppliers and/or co-generation

• Establish contingency plans and procedures in the eventof supply failure. This takes into account food safetyissues

• Identify common methods and equipment for generatingutilities for use on-site. This typically includes steamgeneration and other utilities as appropriate for a givenproduction facility

• Where boilers are operated on-site, identify relevantlicensing requirements to be met by operators asappropriate to boiler types and relevant issuing authority

• Given existing energy and utility supply arrangements,determine the most efficient scheduling of production tomeet the dual objectives of production outcomes andefficient energy/utility use

• Monitor energy and utility usage rates of a givenproduction facility and identify variances againstbudget/plan

• Identify factors that affect the efficient use of energy andutilities. This includes but is not limited to:• features of process/system configuration and design

that conserve and/or recycle energy and utilities suchas steam, heat and water

• poor maintenance which can result in losses such assteam, glycol or ammonia leaks etc

• procedures for shutting down plant and equipment. Forexample, equipment left running during breaks

• procedures for conserving resources not directlyrelated to the process such as lighting, airconditioning

• Assess the impact of these factors on energy and utilityutilisation for a given production facility and identify




opportunities to improve efficiency. Based on thisinvestigation, develop improvement proposals. Thisproject may be undertaken with input from relevanttechnical specialists

• Assess and/or develop procedures to support efficientenergy and utility utilisation. This measure of efficiencyneeds to take account of impact on process equipment,health and safety and food safety

• Establish and/or utilise consultative arrangements tocanvass input on energy and utility efficiency includinginput on waste identification and reduction and options forimproved efficiency

• Communicate information on changes to workplacesystems and procedures to support improvements


Pre-requisite units






• Company information on energy and resource utilisation• Details of contractual arrangements with suppliers• Production scheduling requirements and systems• Energy and resource utilisation information recording

systems, requirements and procedures





FDFTECWTP4A Manage water treatment processesUnit Descriptor This unit covers the knowledge required to treat water for use in

production stages such as washing and cooling and to treat wastewater.

This unit is designed to provide an overview of water treatmentmethods and responsibilities across a food production site. It is notdesigned to meet the competency requirements of the person whospecifies water quality standards and/or treatment methods.

Prerequisite Unit(s) FDFOPTENV3A Monitor the implementation of environmentalmanagement policies



1. Manage water treatmentprocesses

1.1 Uses of water within the plant and the related qualityrequirement for each use are identified

1.2 Appropriate treatment methods are in place to meettreatment requirements

1.3 Procedures for treating water are developed and/orreviewed

2. Manage waste watertreatment and disposal

2.1 Sources and characteristics of waste water generatedacross food processing operations are identified

2.2 Methods for treating and recycling water are identified2.3 Appropriate treatment methods are in place to meet

treatment requirements2.4 Legal requirements for water discharge are identified2.5 Factors affecting the cost of water discharge are identified

and monitored2.6 Conditions that could result in non-compliance and the

related control methods in place to prevent this fromoccurring are established

2.7 Procedures for treatment of waste water are developedand/or reviewed to ensure compliance with trade wastestandards

2.8 Opportunities to reduce the volume of trade waste andimprove treatment methods are identified, investigatedand implemented within level of responsibility


FDFTECWTP4A Manage water treatment processes


RANGE STATEMENT


Range description • Water treatment and related work processes areconsistent with company policies and procedures,regulatory and licensing requirements, legislativerequirements, and industrial awards and agreements andtakes account of OHS and environmental impact

• Procedures for waste water treatment include safetyinformation and procedures to respond to non-complianceand emergency situations

• Follow up action in response to out-of-specificationresults occurs in consultation with the relevantquality/technical expert responsible for packagingspecifications




EVIDENCE GUIDE


Ability to: • Map the uses of water in production across theproduction site. This can include but is not limited toactivities such as water used in cooling applications,washing/flushing

• Identify treatment requirements and methods for waterused in production. This may include addition of sanitizingagents such as chlorine and anti-rust agents

• Identify causes of risks associated with Legionella andrelated control measures

• Describe the meaning of terms and concepts used todescribe water quality. This includes:• potable• total residual chlorine• free residual chlorine• available chlorine

• Identify acceptable limits for water going to storm water(pH range)

• Identify the legal, social and environmental consequencesof releasing water to the environment that does not meetwater quality standards

• Identify characteristics that are monitored in waste waterand how these affect the cost of trade waste disposal.This is set out in agreements with the water supplier andtypically includes volume, BOD, suspended solids, andnitrogen. Some types of heavy metals may also bemonitored although this may not directly affect cost ofdisposal

• Identify equipment and methods used to monitor wastewater characteristics. This includes meters used tomeasure volume and a sampling and testing regime tocheck water quality

• Describe principles of common methods used to treattrade waste and identify typical applications. This includesboth primary and secondary treatment stages. Primarytreatment stages include but are not limited to separation,filtration, sedimentation (settling tanks), and dissolved airfloatation (DAF). Secondary processes include but arenot limited to activated sludge and trickling filter systems

• Identify conditions that could result in failure to complywith legal requirements for storm water and relatedcontrol methods. A typical example could be spill controlconsequences and control methods

• Identify conditions that could result in high costs of tradewaste disposal and related control methods. This couldinclude conditions or activities that place additional loadon treatment processes such as use of strong cleaningchemicals and related control measures

• Develop and/or review procedures to describeprocedures to minimise costs of trade waste disposal.




This includes good housekeeping practices includingcollection of solids and materials rather than hosing themdown drains

• Identify the rights of relevant authorities to enter the siteand conduct independent sample collection and testprocedures

• Identify appropriate communication and consultationsystems to support continuous improvement of resourceefficiency and waste management

• Identify trends in environmental management and socialexpectations of companies and assess the companyenvironmental policy and related procedures in light ofthese trends

• Map the drainage points across a production site. Thisincludes identifying drains that go to bunded areas, tradewaste and storm water

• Map the waste water generated at each stage of the foodprocessing operation. For each stream generated, identifythe characteristics of waste water and related treatmentrequirements

• Carry out an assessment on water use within a givenprocess. Identify the quantities and applications of water;the treatment stages if any; points where water could bemore effectively conserved such as running hoses, steamleaks, and waste water generated by the process. Alsoidentify the treatment methods currently in place.Consider opportunities to improve resource utilisationthrough conservation of water, changing materials andprocessing methods and/or more effective treating and/orrecycling of waste water. Based on this investigation,develop improvement proposals. This project may beundertaken with input from relevant technical specialists

• Establish and/or utilise consultative arrangements tocanvass input on efficient water use and trade wastetreatment methods

• Communicate information on changes to workplacesystems and procedures to support improvements


Pre-requisite units


• FDFOPTENV3A Monitor the implementation ofenvironmental management policies and procedures








• Company environmental policy and related procedures• Site plans including relevant advice on drainage system• Advice on environmental hazards and control procedures

relevant to the production facility• Incident and emergency response procedures and

equipment• Workplace information recording systems, requirements

and procedures





FDF03 Food Processing Industry Training PackageFood Processing Sector

Volume 2 of 5

FDF03 Food Processing Industry Training PackageFood Processing Sector

Volume 2 of 5