Unit of competency details

Unit descriptor

This unit has covers the skills and knowledge required to prepare for, conduct and monitor rectification processes in wine production.

Application of the unit

This unit applies to cellar operations staff required to operate a rectification process. Product and materials may include a range of distillation products and by-products, including low wine, heads, fusel oil and oil of wine. The unit covers managing the equipment and process, monitoring, routine and emergency shutdowns, and keeping of records.

Prerequisite units

FDFCEL2004A

Perform single column lees stripping (continuous still brandy) operations*

FDFOP2004A Clean and sanitise equipment

FDFOP2013A Apply sampling procedures

MSL973001A Perform basic tests

FDFCEL2012A

Handle spirits*

FDFCEL2019A Carry out transfer operations

Employability skills

This unit contains employability skills.

Elements describe the essential outcomes of a unit of competency.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the required skills and knowledge section and the range statement. Assessment of performance is to be consistent with the evidence guide.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare the rectification process for operation

1.1. Product and materials are confirmed and available to meet production requirements

1.2 Product and materials are prepared to meet production requirements

1.3 Services are confirmed as available and ready for operation

1.4 Equipment is checked to confirm readiness for use

1.5 The process is set to meet production requirements

2. Operate and monitor the rectification process

2.1 The rectification process is started up according to workplace procedures

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

2.3 Product and process meet specification

2.4 Equipment is monitored to confirm operating condition

2.5 Out-of-specification product, process and equipment performance is identified, remedied and/or reported

3. Shut down the rectification process

3.1 The process is shut down according to workplace procedures

3.2 Equipment is dismantled and/or prepared for cleaning

3.3 Work is conducted in accordance with workplace environmental guidelines

4. Record information

4.1 Workplace information is recorded in the appropriate format

This section describes the skills and knowledge required for this unit.

Required skills include:

Note: The following required skills should be applied as appropriate to the equipment and processes that are used in the particular winery or workplace.

Ability to: 

• access workplace information to identify distillation requirements
• select, fit and use personal protective clothing and/or equipment
• confirm supply of necessary product, materials and services. This may include checking temperature and alcoholic strength
• liaise with other work areas
• prepare product and materials as required. This may include heating the incoming product
• confirm equipment status and condition. This may include checking:

• computer operation
• air pressure from compressor
• fuel intake
• water flow to condensers
• receiver vessels for product and by-products

• set up and start up the process. This will include any tests or procedures required to meet Customs and Excise regulations
• monitor the process and equipment operation to identify out-of-specification results or non-compliance. This may involve monitoring:

• wine feed
• alcohol content of the feed
• steam input
• cooling water flow rates to condensers
• volume of charge
• temperature of distillate
• alcoholic strength of distillate
• heat source
• reflux temperatures
• temperature of incoming wine
• temperatures throughout still and/or column
• temperatures and strengths at take-off points
• receivers for heads, hearts and tails
• evaporation rates
• charge characteristics
• pressure of still and/or column
• condensate rate or flow

• monitor supply and flow of product, materials and services to and from the process
• take corrective action in response to out-of-specification results or non-compliance
• report and/or record corrective action as required
• conduct product and batch changeovers
• take samples and conduct tests
• shut down equipment in response to an emergency situation
• shut down equipment in response to routine shutdown requirements
• prepare equipment for cleaning. This may involve draining and/or dismantling equipment, and removing waste either manually or by rinsing, in preparation for cleaning and sanitation
• record workplace information. This will include meeting the requirements of Customs and Excise regulations
• maintain work area to meet housekeeping standards
• ensure that all Customs and Excise regulations are adhered to
• sort, collect, treat, recycle or dispose of waste according to enterprise procedures
• manually clean and sanitise equipment according to enterprise procedures
• clean and sanitise equipment according to enterprise procedures
• carry out routine maintenance according to enterprise procedures
• carry out transfer operations according to enterprise procedures
• perform heat exchange operations according to enterprise procedures
• identify, rectify and/or report environmental non-compliance according to enterprise procedures
• use oral communication skills/language to fulfil the job role as specified by the organisation, including questioning, active listening, asking for clarification and seeking advice from supervisor
• work cooperatively within a culturally diverse workforce

Required knowledge includes:

Note: The following required knowledge should be applied as appropriate to the equipment and processes that are used in the particular winery or workplace.

Knowledge of: 

• purpose and principles of rectification, including definition of the following terms:

• distillation
• continuous columns
• fractionation
• bubble tower
• bubble caps or plates
• sieve trays or plates
• packed column

• types and operation of different columns used for rectification. This should include:

• structure and operation
• purpose of each column
• effect of each column on characteristics of end product

• factors affecting distillation column operation. This may include:

• feed conditions
• reflux conditions
• vapour flow conditions
• foaming
• entrainment
• weeping or dumping
• flooding
• column diameter
• state of trays and packings
• weather conditions

• process requirements for cuts taken from each column. This may include:

• heads (or feints)
• tails or fusel oils
• oil of wine
• methanol
• highly rectified spirit (SVR)

• link to related processes. This will include the fermentation or preparation of the product to be distilled and any further processing requirements of the distillate
• stages and changes which occur during distillation. This will include critical temperatures and specific components affected
• effect of process stages on distillate and by-products
• quality characteristics and uses of distillate and by-products
• product and materials preparation requirements and effect of variation on the process
• process specifications, procedures and operating parameters
• equipment and instrumentation components, purpose and operation
• basic operating principles of process control systems where relevant
• sampling and testing procedures
• services used
• significance and method of monitoring control points within the process
• common causes of variation and corrective action required
• Occupational Health and Safety (OHS) hazards and controls. This will include:

• the dangerous properties of ethyl alcohol
• emergency flooding procedures
• emergency evacuation procedures
• handling procedures of spirits

• lock-out and tag-out procedures
• procedures and responsibility for reporting problems
• environmental issues and controls
• shutdown and cleaning requirements associated with changeovers and types of shutdowns
• recording requirements and procedures
• operation of Customs and Excise regulations
• waste handling requirements and procedures where relevant
• cleaning and sanitation procedures where relevant
• routine maintenance procedures where relevant
• transfer procedures where relevant
• heat exchange procedures where relevant

EVIDENCE GUIDE

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Assessment must be carried out in a manner that recognises the cultural and literacy requirements of the assessee and is appropriate to the work performed. Competence in this unit must be achieved in accordance with food safety standards and regulations.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence of the ability to:

• use personal protective equipment and follow other specified OHS procedures
• prepare and confirm status of equipment before commencing rectification
• monitor rectification process control points and equipment
• take corrective action in response to out-of-specification results or non-compliance
• perform routine and emergency shutdowns
• demonstrate knowledge of OHS hazards, controls and emergency procedures
• record information appropriately.

Context of and specific resources for assessment

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

• personal protective clothing and equipment as required
• work procedures, including advice on company practices, safe work practices, food safety, quality and environmental requirements
• instructions, information, specifications and schedules as required
• equipment, services and corresponding information as required
• products and materials as required
• internal and external customers and suppliers as required
• cleaning procedures, materials and equipment as required
• documentation and recording requirements and procedures.

Method of assessment

This unit should be assessed together with core units and other units of competency relevant to the function or work role.

Guidance information for assessment

To ensure consistency in one's performance, competence should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances, cases and responsibilities, and where possible, over a number of assessment activities.

RANGE STATEMENT

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Policies and procedures 

Work is carried out in accordance with workplace procedures, licensing requirements and legislative requirements

Workplace information 

Workplace information can include:

• Standard Operating Procedures (SOPs)
• specifications
• production schedules and instructions
• work notes
• Material Safety Data Sheets (MSDS)
• manufacturer instructions
• verbal direction from manager, supervisor or senior operator

Equipment 

Rectification equipment may include:

• analyser column
• purifier column
• rectifier column
• methanol column
• pasteuriser
• pumps
• lines and fittings
• valves
• flow meters
• heat exchangers
• pressure vessels,
• compressors
• condensers
• test equipment (e.g. hydrometers and, thermometers)
• monitoring equipment

Product and materials 

Product and materials may include:

• a range of distillation products and by-products, including low wine, heads, fusel oil and oil of wine

Services 

Services may include:

• power
• water (hot and cold )
• steam
• fuel

Confirming equipment status 

Confirming equipment status involves:

• checking that hygiene and sanitation standards, safety standards and pre-start requirements are met and that equipment is operational
• checking the operation and calibration status of measuring instrumentation

Monitoring the process 

Monitoring the process may involve:

• the use of production data, such as performance control charts (manual or computerised)
• sampling
• sensory evaluation
• analytical tests

Process set up, operation and monitoring functions 

Process set up, operation and monitoring functions may be:

• manual or involve the use of a process control system

Control points 

Control points refer to those key points in a work process that must be monitored and controlled. This includes:

• food safety (critical)
• quality and regulatory control points
• inspection points

Information systems 

Information systems may be:

• print or screen based

Work hazards 

Work may involve exposure to:

• chemical, dangerous or hazardous substances

Unit sector

Cellar operations