Assessment Requirements for FBPOPR2036 Operate an extrusion process

Release: 1

Assessment Requirements for FBPOPR2036 Operate an extrusion process

Modification History

Release	Comments
Release 1	This version released with FBP Food, Beverage and Pharmaceutical Training Package Version 1.0

Performance Evidence

An individual demonstrating competency in this unit must satisfy all of the elements and performance criteria of this unit.

There must be evidence that the individual has operated an extrusion process on at least one occasion, including:

accessing workplace information to identify processing requirements

selecting, fitting and using personal protective clothing and/or equipment

confirming supply of necessary materials/ingredients and services

conducting pre-start checks, including:

inspecting equipment condition to identify any signs of wear

selecting and fitting appropriate attachments where required

setting processing parameters

cancelling isolation or lock-outs as required

confirming that equipment is clean and correctly configured for processing requirements

positioning sensors and controls correctly

ensuring any scheduled maintenance has been carried out

confirming that all safety guards are in place and operational

starting, operating, monitoring and adjusting process equipment to achieve required outcomes, including monitoring control points and conducting inspections as required at each stage of the extrusion process to confirm process remains within specification, including:

parameters, including throughput

load/work input as measured by rpm (revolutions per minute)

kilowatts

amps and/or Hz (hertz) at each stage of the process

monitoring supply of materials to and from the extrusion process

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

responding to and/or reporting equipment failure within level of responsibility

locating emergency stop functions on equipment

following isolation and lock-out/tag-out procedures as required to take process and related equipment off-line in preparation for cleaning and/or maintenance within level of responsibility

completing workplace records as required

maintaining work area to meet housekeeping standards

using process control systems according to workplace procedures

cleaning and sanitising equipment according to workplace procedures

following relevant work health and safety procedures.

Knowledge Evidence

An individual must be able to demonstrate the knowledge required to perform the tasks outlined in the elements and performance criteria of this unit. This includes knowledge of:

purpose and basic principles of each part of the process, including the purpose and methods used to achieve each stage of the extrusion process

basic operating principles of equipment used for the extrusion process, including:

main equipment components

status and purpose of guards

equipment operating capacities and applications

the purpose and location of sensors and related feedback instrumentation

services required for the extrusion process and action to take if services are not available

the flow of the extrusion process and the effect of outputs on downstream processes

quality characteristics of extruded output, including required characteristics of mass or blend to be extruded, including:

gelatinisation and viscosity

dimensions, texture and hardness of extruded product

moisture content

effect of variation in inputs and/or services on process performance

operating requirements and parameters and corrective action required where operation is outside specified operating parameters, including the effect of variation in key variables, including:

throughput and work input at each stage of the process

effect of time and temperature

barrel pressures and temperatures at each zone

typical equipment faults for the extrusion process and related causes, including signs and symptoms of faulty equipment and early warning signs of potential problems, including:

screw and barrel assembly wear

die plate wear

wear of conditioner paddles

extruder knife condition

methods used to monitor the extrusion process, including inspecting, measuring and testing as required by the process

inspection or test points (control points) in the process and the related procedures and recording requirements

common causes of variation in the operation of the extrusion process and corrective action required

contamination risks related to the extrusion process and related control measures

work health and safety hazards and controls relevant to the operation of the extrusion process

requirements of different shutdowns as appropriate to the process and workplace production requirements, including emergency and routine shutdowns and procedures to follow in the event of a power outage

isolation, lock-out and tag-out procedures and responsibilities required for the operation of the extrusion process

procedures and responsibility for reporting production and performance information

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

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

cleaning and sanitation procedures required for the extrusion process.

Assessment Conditions

Assessment of skills must take place under the following conditions:

physical conditions:

a workplace or an environment that accurately represents workplace conditions

resources, equipment and materials:

personal protective clothing and equipment

extrusion and related equipment and services

ingredients/blend/mass to be extruded

sampling schedules and test procedures and equipment

cleaning procedures, materials and equipment

specifications:

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

documentation and recording requirements and procedures.

Assessors of this unit must satisfy the requirements for assessors in applicable vocational education and training legislation, frameworks and/or standards.

Links

Companion Volumes, including Implementation Guides, are available at VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=78b15323-cd38-483e-aad7-1159b570a5c4