Unit of competency Outline
Date retreived
22/07/2026 6:00 PM AWST
22/07/2026 6:00 PM AWST
Whilst all efforts are made to provide accurate and timely information from the relevant source/documentation, please be aware that the information supplied may not be the most current version. The accuracy of the detail has not been confirmed by the Department and therefore should not be relied upon without first confirming the contents.
Produce products using twin screw extruders
Produce products using twin screw extruders
Unit of competency
National Code
PMBPROD334A
PMBPROD334A
State Code
W7646
W7646
TGA Status
Replaced
Replaced
DTWD Status
Replaced
Replaced
State Implementation and Classification
Approved Date
Field of Education
030305 - Materials Engineering
Original Release Date
Nominal Hours
70
Description
This competency covers the operation and adjustment of twin screw extrusion equipment and extrusion processes and the solving of non-routine problems. It applies to extrusion processes for pipe, sheet, profile, film, cable and rod. It usually applies to products extruded from dry blend PVC powder/resin and other materials.
Notes
Elements and Performance Criteria
1. Plan own work requirements.
- 1.1 Identify the most appropriate equipment to be used for production process, upstream and downstream operations from production plan or request.
- 1.2 Identify and check materials required, including additives and regrind and their amounts or percentages.
- 1.3 Implement measures to control identified hazards in line with procedures and duty of care.
- 1.4 Identify requirements for materials, quality, production and equipment checks.
2. Start up twin screw extrusion process to procedures.
- 2.1 Identify process settings required for product.
- 2.2 Set process to required settings.
- 2.3 Check materials are correct.
- 2.4 Take appropriate action for non-conforming materials.
- 2.5 Set up date, batch and materials markings as required.
- 2.6 Complete pre-start checks.
- 2.7 Start up ancillary equipment as required.
- 2.8 Start up extrusion process.
- 2.9 Synchronise/balance system components as required.
3. Operate and make adjustments to the twin screw extrusion process to procedures.
- 3.1 Operate extrusion process, noting key variables.
- 3.2 Monitor controls/displays/terminals for production and process data.
- 3.3 Take samples as required and identify product out of specification.
- 3.4 Monitor product/process quality.
- 3.5 Make adjustments to remedy faults and nonconformity as required.
- 3.6 Establish a stable compounding and extrusion process.
- 3.7 Adjust process to minimise scrap and trim.
- 3.8 Clean, adjust and lubricate equipment as required.
4. Shut down twin screw extruder to procedures.
- 4.1 Determine type of shut down.
- 4.2 Select appropriate purging method.
- 4.3 Purge efficiently and adequately as required.
- 4.4 Leave machine in appropriate condition and with appropriate locks, tags or notices.
- 4.5 Complete relevant documentation.
- 4.6 Ensure area is clean and clear after the shutdown in readiness for the next start up.
5. Anticipate and solve problems.
- 5.1 Recognise a problem or a potential problem.
- 5.2 Determine problems needing priority action.
- 5.3 Refer problems outside area of responsibility to appropriate person, with possible causes.
- 5.4 Seek information and assistance as required to solve problems.
- 5.5 Solve problems within area of responsibility.
- 5.6 Follow through items initiated until final resolution has occurred.
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. Add any 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.
Where reference is made to industry codes of practice and/or Australian/international standards, the latest version must be used.
Context
This competency applies to all work environments and sectors within the plastics, rubber and cablemaking industry. It includes the operation of all relevant ancillary equipment where that equipment is integral to the extrusion process.
Procedures
All operations are performed in accordance with procedures.
Procedures include all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.
Tools and equipment
This competency includes use of equipment and tools such as:
twin screw extruder equipment and components (such as main drive, gear box, thrust assembly, adapter, gate, breaker plate, screen pack, doser, screw/s, barrel, heaters, thermocouples)
vacuum pump, vacuum system
extrusion dies (eg rod, sheet, pipe, profile and cable)
twin screw extruders, including those with parallel, tapered or other screw configurations
auxiliary equipment (eg water pump, feeders, hopper loader, pelletiser, dehumidifiers)
tools for taking samples
relevant personal protective equipment
Materials
This unit applies primarily to dry blended PVC powder, where the materials are 'compounded' within the extruder. For other materials, refer to PMBPROD313C Produce products using single screw extruders.
Hazards
Typical hazards include:
spills
dusts/vapours
slip and fall (eg due to spilt granules)
temperature (eg due to heated barrel, head and die)
volatiles vented from the extruder
hazardous materials, including decomposing polymer during start up and shut down
moving equipment (eg moving moulds, robots and ancillary equipment)
manual handling hazards
equipment operations.
Problems
'Anticipate and solve problems' means resolve a wide range of routine and non-routine problems, using product and process knowledge to develop solutions to problems which do not have a known solution/a solution recorded in the procedures.
Typical routine faults include:
burn marks
flow marks
poor surface finish
poor colour dispersion
blistering
colour contamination
black spots
dimensional changes
high reversion
ovality
bowing.
Non-routine faults, which may have multiple causes include:
product distortion
plateout
residual stresses
intermittent faults.
Typical process and product problems may include:
die/tooling problems such as damage or build-up
equipment malfunction
variations in temperatures, pressures, torque, speeds and times
vacuum performance and volatile venting rates
variations in material properties and/or contamination of materials
variation in material flow rates
processing problems.
Appropriate action for problems outside of area of responsibility may be reporting to an appropriate person.
Appropriate action for solving problems within area of responsibility includes asking questions and seeking assistance from appropriate persons/sources.
Variables
Key variables to be monitored include:
differences between actual and set temperatures
speeds, including screw speed and haul-off
colour and uniformity
surface finish and appearance
product finished thickness
output rate
product integrity and general conformance to specification/sample.
The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Add any 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.
Where reference is made to industry codes of practice and/or Australian/international standards, the latest version must be used.
Context
This competency applies to all work environments and sectors within the plastics, rubber and cablemaking industry. It includes the operation of all relevant ancillary equipment where that equipment is integral to the extrusion process.
Procedures
All operations are performed in accordance with procedures.
Procedures include all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.
Tools and equipment
This competency includes use of equipment and tools such as:
twin screw extruder equipment and components (such as main drive, gear box, thrust assembly, adapter, gate, breaker plate, screen pack, doser, screw/s, barrel, heaters, thermocouples)
vacuum pump, vacuum system
extrusion dies (eg rod, sheet, pipe, profile and cable)
twin screw extruders, including those with parallel, tapered or other screw configurations
auxiliary equipment (eg water pump, feeders, hopper loader, pelletiser, dehumidifiers)
tools for taking samples
relevant personal protective equipment
Materials
This unit applies primarily to dry blended PVC powder, where the materials are 'compounded' within the extruder. For other materials, refer to PMBPROD313C Produce products using single screw extruders.
Hazards
Typical hazards include:
spills
dusts/vapours
slip and fall (eg due to spilt granules)
temperature (eg due to heated barrel, head and die)
volatiles vented from the extruder
hazardous materials, including decomposing polymer during start up and shut down
moving equipment (eg moving moulds, robots and ancillary equipment)
manual handling hazards
equipment operations.
Problems
'Anticipate and solve problems' means resolve a wide range of routine and non-routine problems, using product and process knowledge to develop solutions to problems which do not have a known solution/a solution recorded in the procedures.
Typical routine faults include:
burn marks
flow marks
poor surface finish
poor colour dispersion
blistering
colour contamination
black spots
dimensional changes
high reversion
ovality
bowing.
Non-routine faults, which may have multiple causes include:
product distortion
plateout
residual stresses
intermittent faults.
Typical process and product problems may include:
die/tooling problems such as damage or build-up
equipment malfunction
variations in temperatures, pressures, torque, speeds and times
vacuum performance and volatile venting rates
variations in material properties and/or contamination of materials
variation in material flow rates
processing problems.
Appropriate action for problems outside of area of responsibility may be reporting to an appropriate person.
Appropriate action for solving problems within area of responsibility includes asking questions and seeking assistance from appropriate persons/sources.
Variables
Key variables to be monitored include:
differences between actual and set temperatures
speeds, including screw speed and haul-off
colour and uniformity
surface finish and appearance
product finished thickness
output rate
product integrity and general conformance to specification/sample.
The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, the range statement and the assessment guidelines for this training package.
Overview of assessment
A holistic approach should be taken to the assessment.
Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the Elements, Performance Criteria and skills and knowledge.
Where the assessee does not currently posses evidence of competency in PMBPROD213B Operate extruders, it may be co-assessed with this unit.
Critical aspects for assessment and evidence required to demonstrate competency in this unit
It is essential that competence is demonstrated in the knowledge and skills defined in this unit. These may include the ability to:
identify critical materials properties and extrusion process characteristics in relation to the process requirements and the end product
make adjustments to the process as required
identify and take appropriate action on problems and potential problems.
Consistent performance should be demonstrated. For example, look to see that:
extrusion production quality and output standards are met consistently the process runs consistently and smoothly, with the minimum need for human intervention
all safety procedures are adhered to.
Assessment method and context
It is preferred that assessment takes place on an industrial extruder in a work-like environment.
Competence in this unit may be assessed:
by using an appropriate, industrial twin screw extrusion system requiring demonstration of start-up, operation and shutdown procedures
in a situation allowing for the generation of evidence of the ability to recognise, anticipate and respond to problems
by using a suitable simulation and/or a range of case studies/scenarios
through a combination of these techniques.
In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practical/simulation or similar assessment.
Resource implications
This section should be read in conjunction with the Range Statement for this unit of competency. Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation. A bank of case studies/scenarios and questions will also be required to the extent that they form part of the assessment method. Questioning may take place either in the workplace, or in an adjacent, quiet facility such as an office or lunchroom. No other special resources are required.
Overview of assessment
A holistic approach should be taken to the assessment.
Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the Elements, Performance Criteria and skills and knowledge.
Where the assessee does not currently posses evidence of competency in PMBPROD213B Operate extruders, it may be co-assessed with this unit.
Critical aspects for assessment and evidence required to demonstrate competency in this unit
It is essential that competence is demonstrated in the knowledge and skills defined in this unit. These may include the ability to:
identify critical materials properties and extrusion process characteristics in relation to the process requirements and the end product
make adjustments to the process as required
identify and take appropriate action on problems and potential problems.
Consistent performance should be demonstrated. For example, look to see that:
extrusion production quality and output standards are met consistently the process runs consistently and smoothly, with the minimum need for human intervention
all safety procedures are adhered to.
Assessment method and context
It is preferred that assessment takes place on an industrial extruder in a work-like environment.
Competence in this unit may be assessed:
by using an appropriate, industrial twin screw extrusion system requiring demonstration of start-up, operation and shutdown procedures
in a situation allowing for the generation of evidence of the ability to recognise, anticipate and respond to problems
by using a suitable simulation and/or a range of case studies/scenarios
through a combination of these techniques.
In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practical/simulation or similar assessment.
Resource implications
This section should be read in conjunction with the Range Statement for this unit of competency. Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation. A bank of case studies/scenarios and questions will also be required to the extent that they form part of the assessment method. Questioning may take place either in the workplace, or in an adjacent, quiet facility such as an office or lunchroom. No other special resources are required.
Replaced By
| State Code | National Code | Title | Type |
|---|---|---|---|
| BAI52 | PMBPROD334 | Produce products using twin screw extruders | Unit of competency |
| State Code | National Code | Title | Type |
|---|---|---|---|
| W400 | PMB30107 | Certificate III in Polymer Processing | Qualification |
| W401 | PMB40107 | Certificate IV in Polymer Technology | Qualification |