Elements and Performance Criteria

Range description
Work is carried out according to company policies and procedures, regulatory and licensing requirements, legislative requirements, and industrial awards and agreements
Legislative requirements are typically reflected in procedures and specifications. Legislation relevant to the industry includes the Food Standards Code including labelling, weights and measures legislation; and legislation covering food safety, environmental management, occupational health and safety, anti-discrimination and equal opportunity. When applied to the pharmaceutical industry, relevant GMP codes apply in place of the Australian Food Standards Code and reference to food safety is replaced by GMP
Workplace information may include Standard Operating Procedures (SOPs), specifications, production schedules and instructions, manufacturers' advice, standard forms and reports
The extrusion process typically includes feeding/dosing, conditioning/cooking, mixing, extruding, drying and cooling. It may also involve screening/sieving, a final additive addition stage and further processing such as sheeting or aeration according to product type
Extrusion equipment may include ingredients handling and addition equipment, mixers, conditioners, cookers, dryers and coolers. Some systems may also include expanders; oil coating systems; screens and sieves; and sheeting, cutting/stamping equipment; tray feeders/take off; and stackers
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 procedures should be used to customise the details of this unit. Where more detailed changeovers are carried out, also refer to
Shutdown procedures may include cleaning. In some cases cleaning may be carried out by a dedicated cleaning crew
Services may need to be confirmed. These depend on the nature of the process. Typical examples include power, steam, water, vacuum, and compressed and instrumentation air

Ability to:
Access workplace information to identify processing requirements
Select, fit and use personal protective clothing and/or equipment
Confirm supply of necessary materials/ingredients and services
Conduct pre-start checks. This may involve inspecting equipment condition to identify any signs of wear; selecting and fitting appropriate attachments where required; setting processing parameters; cancelling isolation or lockouts as required; confirming that equipment is clean and correctly configured for processing requirements; sensors and controls are correctly positioned; any scheduled maintenance has been carried out, and that all safety guards are in place and operational
Start, operate, monitor and adjust process equipment to achieve required outcomes. This may include monitoring control points and conducting inspections as required at each stage of the extrusion process to confirm process remains within specification. It may also involve monitoring parameters such as throughput, and load/work input as measured by rpm (revs per minute), kilowatts, amps and/or Hz (hertz) at each stage of the process
Monitor supply of materials to and from the extrusion 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 process and related equipment off-line in preparation for cleaning and/or maintenance within level of 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
Collect samples and conduct tests
Clean and sanitize equipment

Knowledge of:
Purpose and basic principles of each part of the process. This includes an understanding of the purpose and methods used to achieve each stage of the extrusion process
Basic operating principles of equipment. This may include an operational understanding of main equipment components; status and purpose of guards; equipment operating capacities and applications; and the purpose and location of sensors and related feedback instrumentation. It also includes knowledge of services required 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. This may include:

required characteristics of mass or blend to be extruded such as 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. This includes an understanding of the effect of variation in key variables such as:

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 and related causes. This includes recognition of signs and symptoms of faulty equipment and early warning signs of potential problems such as screw and barrel assembly wear, die plate wear, wear of conditioner paddles and extruder knife condition
Methods used to monitor the extrusion process. This may include inspecting, measuring and testing as required by the process. It requires awareness of inspection or test points (control points) in the process and the related procedures and recording requirements
Common causes of variation and corrective action required
Contamination risks related to the extrusion process and related control measures
OHS hazards and controls
Requirements of different shutdowns as appropriate to the process and workplace production requirements. This includes emergency and routine shutdowns and procedures to follow in the event of a power outage
Product/process changeover procedures and responsibilities
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 extrusion process. This includes waste/rework collection and handling procedures related to the process

May include knowledge of:

Basic operating principles of process control where relevant. This includes the relationship between control panels and systems and the physical equipment
Sampling and testing associated with process monitoring and control
Routine maintenance procedures
Cleaning and sanitation procedures

Relationship with other standards
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 other units of competence relevant to the function or work role. In addition, the following optional or ancillary units may be relevant:

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

Resources required 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
Extrusion and related equipment and services
Ingredients/blend/mass to be extruded
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 standard and who can assess, refer to the Assessment Guidelines for this Training Package.