FDFGPS2008A Operate a neutralisation process

Revision Number: 1

FDFGPS2008A Operate a neutralisation process

Modification History

Not applicable.

Unit Descriptor

Unit descriptor	This unit of competency covers the skills and knowledge required to set up, operate, adjust and shut down a neutralisation process to remove impurities from crude oils.

Application of the Unit

Application of the unit	This unit has application in an edible oils production environment. It typically targets the production worker responsible for applying basic operating principles to the operation and monitoring of a neutralisation process. Processes may be batch or continuous, and apply to single or multiple product types. When batch or product changeover procedures are part of this work process, the procedures should be used to customise the application of this unit. Where more detailed changeovers are carried out, FDFOP2011A Conduct routine maintenance, should be considered.

Licensing/Regulatory Information

Not applicable.

Pre-Requisites

Prerequisite units

Employability Skills Information

Employability skills	This unit contains employability skills.

Elements and Performance Criteria Pre-Content

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.

Elements and Performance Criteria

ELEMENT	PERFORMANCE CRITERIA
1. Prepare the neutralisation equipment and process for operation	1.1. Materials are confirmed and available to meet operating requirements 1.2. Cleaning and maintenance requirements and status are identified and confirmed 1.3. Processing/operating parameters are entered as required to meet safety and production requirements 1.4. Equipment performance is checked and adjusted as required 1.5. Pre-start checks are carried out as required by workplace requirements
2. Operate and monitor the neutralisation process	2.1. The process is started and operated according to workplace procedures 2.2. Equipment is monitored to identify variation in operating conditions 2.3. Variation in equipment operation is identified and maintenance requirements are reported according to workplace reporting requirements 2.4. The process is monitored to confirm that neutralised product meets soap target specifications 2.5. Out-of-specification product/process outcomes are identified, rectified and/or reported to maintain the process within specification 2.6. The work area is maintained according to housekeeping standards 2.7. Work is conducted in accordance with workplace environmental guidelines 2.8. Workplace records are maintained according to workplace recording requirements
3. Shut down the neutralisation process	3.1. The appropriate shutdown procedure is identified 3.2. The process is shut down according to workplace procedures 3.3. Maintenance requirements are identified and reported according to workplace reporting requirements

Required Skills and Knowledge

REQUIRED SKILLS AND KNOWLEDGE
This section describes the skills and knowledge required for this unit.
Required skills
Ability to: access workplace information to identify neutralisation process requirements select, fit and use personal protective clothing and/or equipment confirm supply of necessary oil, materials and services conduct pre-start checks, such as inspecting equipment condition to identify any signs of wear, confirming availability of tank space, selecting appropriate settings and/or related parameters, cancelling isolation or lock outs as required, confirming that equipment is clean and correctly configured for neutralisation process requirements, positioning sensors and controls correctly, ensuring any scheduled maintenance has been carried out, and confirming that all safety guards are in place and operational start, operate, monitor and adjust neutralisation process equipment to achieve required outcomes, including monitoring control points and conducting inspections as required to confirm process remains within specification, such as: oil temperature pressures flow rates/quantity chemical dosage rate product quality monitor supply and flow of materials to and from the neutralisation process take corrective action in response to out-of-specification results 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 neutralisation process and related equipment off-line in preparation for cleaning and/or maintenance within level of responsibility demonstrate batch/product changeovers as required complete workplace records as required maintain work area to meet housekeeping standards use process control systems according to enterprise procedures collect samples and conduct tests according to enterprise procedures conduct routine maintenance according to enterprise procedures clean and sanitise equipment according to enterprise procedures use oral communication skills/language competence to fulfil the job role as specified by the organisation, including questioning, active listening, asking for clarification and seeking advice from supervisor work cooperatively within a culturally diverse workforce
Required knowledge
Knowledge of: purpose and basic principles of the neutralisation process, including the type of alkali used, and the degumming process to prepare oil for neutralisation basic operating principles of equipment, such as main equipment components, status and purpose of guards, equipment operating capacities and applications, and the purpose and location of sensors and related feedback instrumentation services required and action to take if services are not available the flow of the neutralisation process and the effect of outputs on downstream edible oils and fats processes quality characteristics to be achieved by the neutralisation process quality requirements of inputs and effect of variation in oil quality on neutralisation process performance operating requirements and parameters and corrective action required where operation is outside specified operating parameters typical equipment faults and related causes, including signs and symptoms of faulty equipment and early warning signs of potential problems methods used to monitor the neutralisation process, such as inspecting, measuring and testing as required by the process inspection or test points (control points) in the neutralisation process and the related procedures and recording requirements contamination/food safety risks associated with the neutralisation process and related control measures common causes of variation and corrective action required occupational health and safety (OHS) hazards and controls requirements of different shutdowns as appropriate to the neutralisation 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 procedures and responsibility for reporting production and performance information neutralisation process changeover procedures and responsibilities environmental issues and controls relevant to the neutralisation process, including waste/rework collection and handling procedures related to the process basic operating principles of process control, where relevant, including the relationship between control panels and systems and the physical equipment sampling and testing associated with neutralisation process monitoring and control where relevant routine maintenance procedures where relevant cleaning and sanitation procedures where relevant

Evidence Guide

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 ability to: conduct pre-start checks on machinery used for neutralisation start, operate, monitor and adjust process equipment to achieve required quality outcomes take corrective action in response to typical faults and inconsistencies complete workplace records as required apply safe work practices and identify OHS hazards and controls safely shut down equipment apply food safety procedures to work practices.
Context of and specific resources for assessment	Assessment must occur in a real or simulated workplace where the assessee has access to: personal protective clothing and equipment work procedures, including advice on safe work practices, food safety, quality and environmental requirements information on equipment capacity and operating 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 as required documentation and recording requirements and procedures cleaning procedures, materials and equipment as required.
Method of assessment	This unit should be assessed together with core units and other units of competency relevant to the function or work role. Examples could be: FDFOP2003A Clean equipment in place FDFOP2004A Clean and sanitise equipment FDFOP2011A Conduct routine maintenance FDFOP2013A Apply sampling procedures FDFOP2030A Operate a process control interface MSL973001A Perform basic tests.
Guidance information for assessment	To ensure consistency in one's performance, competency should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances, cases and responsibilities, and where possible, over a number of assessment activities.

Range Statement

RANGE STATEMENT
The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.
Policies and procedures	Work is carried out according to company policies and procedures, regulatory and licensing requirements, legislative requirements, and industrial awards and agreements
Legislative requirements	Legislative requirements are typically reflected in procedures and specifications. Legislation relevant to this industry includes: the Food Standards Code, including labelling, weights and measures legislation legislation covering food safety, environmental management, OHS, anti-discrimination and equal opportunity
Workplace information	Workplace information may include: standard operating procedures (SOPs) specifications production schedules and instructions manufacturers' advice standard forms and reports
Neutralisation equipment	Neutralisation equipment may include: tanks pumps centrifugal separators vacuum dryer chemical addition system heat exchanger
Materials	Materials used in neutralisation may include: crude oil hot water phosphoric acid sodium hydroxide citric acid
Operation of equipment and processes	Operation of equipment and processes may require: the use of process control panels and systems
Shutdown procedures	Shutdown procedures may include: cleaning (in some cases cleaning may be carried out by a dedicated cleaning crew)
Services	Services may need to be confirmed. These depend on the nature of the process. Typical examples include: power steam vacuum water compressed and instrumentation air

Unit Sector(s)

Unit sector	Grocery products and supplies

Competency field

Competency field

Co-requisite units

Co-requisite units