Flour Operations

Food
Processing
Industry
FDF 98
Flour Milling
Competency
Units
NATIONAL FOOD INDUSTRY

TRAINING COUNCIL
Qualification Code
Certificate III in Food Processing FDF30198
Certificate II in Food Processing FDF20198
Certificate I in Food Processing FDF10198
© Australian National Training Authority 5

FDF 98
Operate a scratch and sizing process
© Australian National Training Authority
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FDF 98
INDEX TO: Flour Milling Units
UNIT CODE UNIT TITLE PAGE NO.
FDF FMDC1 A Locate industry and company products and 1

processes (Flour Milling)
FDF FMSS2 A Operate a scratch and sizing process 5
FDF FMSG2 A Operate a scalping and grading process 9
FDF FMRP2 A Operate a reduction process 13
FDF ZZFR2 A Operate a grain receival process 17
FDF ZZFB2 A Operate a flour blending process 21
FDF FMPP2 A Operate a purification process 25
FDF ZZPM2 A Operate a flour pre-mix process 29
FDF FMCO2 A Operate a grain conditioning process 33
FDF FMGC2 A Operate a grain cleaning process 37
FDF FMWB2 A Operate a wheat break process 41
FDF FMOS3 A Operate a system (Flour Milling) 45

FDF 98

FDF 98
Locate industry and company products and

FDF FMDC1 A processes (Flour Milling)
Descriptor This is a specialist unit that has been customised for the flour
milling sector. It covers the products and processes used in their
workplace.
Range of variables
The range of variables provides further advice to interpret the scope and context of this unit of
competence. It assumes:
– Processes and procedures are carried out within company policy and procedures and legislative
requirements
– Flour milling is carried out within company policy and procedures and legislative requirements
– Flour milling processes will typically include grain blending, conditioning, screening, wheat break,
scalping and grading, scratching and sizing, purifying, reducing, pre-mixing and flour blending
– Stock for the flour milling system is stored and supplied through a silo system
Element Performance criteria Evidence guide – Part A

Identify products and Company product range is Part A of the Evidence guide identifies the
quality products identified knowledge to be demonstrated to confirm
competence for this unit. Part B of the Evidence
Quality requirements of
guide outlines how this guide is to be applied. It
final products are identified
should be read in conjunction with the Range of
in accord with company
variables.
standards
Demonstrated ability to:
– access workplace information to identify
Identify and locate Raw materials and related materials and production requirements
production and handling systems are
– identify and locate materials used in the
packaging processes located and operated as
work process
required
– identify and locate production and/or
Production and packaging packaging stages and processes in the
stages and processes are workplace
identified – comply with OHS and food safety
Equipment used for each requirements when moving around the
stage is located workplace
Underpinning knowledge:
– range of final products produced by the
company
– basic understanding of brand image,
company goals and philosophy
– quality requirements/specifications for final
products
– consequences of product failing to meet
quality requirements
– stages and processes used to manufacture
product
– basic purpose of equipment used at each
stage
– outputs at each stage of the process (cont.)

FDF 98

Underpinning knowledge: (continued)
– raw materials/consumables used
– preparation, packaging, handling and
storage of finished product prior to sale
– OHS, quality, food safety and environmental
requirements relating to own work
Evidence guide – Part B

Assessment guide
• Assessment must take account of the food industry’s endorsed assessment guidelines and may use
the non-endorsed Assessment Framework for the Food and Beverage Processing Industry NFITC
June 1995.
• The competencies described in this unit need to be performed over a specified time and events,
under normal workplace conditions, having due regard for the key assessment principles of validity,
reliability, fairness and flexibility.
• Assessment should be structured on whole of work activities giving emphasis to confirming that the
assessee can achieve the workplace outcomes described in the Performance criteria, including
demonstration of the underpinning knowledge and skills contained in the Evidence guide.
• The equipment used should be the actual items described in the Range of variables and Assessment
context.
• The procedures and documentation should be those typically used in a workplace. Compliance with
statutory occupational health and safety, food safety, hygiene and environmental requirements
relevant to the food processing industry should be emphasised.
• Assessment should not require a higher level of communication competency than that specified in the
core competencies for the particular AQF level.
• Assessment should reinforce the integration of the key competencies and the food industry’s core
competencies for the particular AQF level.
Assessment context
Assessment must occur in a real or simulated workplace. Such an environment must provide an
opportunity for the assessee to describe flour milling products and processes given:
– work procedures including advice on safe work practices, food safety and environmental
requirements
– production systems, stages and processes
– raw materials, in-process and finished product requirements and/or specifications
Relationship to other units

Co-requisites:
– Communicate in the workplace
– Apply basic mathematical concepts
– Apply safe work procedures
– Apply basic quality assurance practices
– Apply basic food safety practices
Relationship to learning resources

Main learning resources:
– Introductory Milling A (Flour Milling)

FDF 98
– Introductory Milling B (Flour Milling)

Related learning resources:
– Industrial Communication A
– Calculations A
– Occupational Health and Safety A
– Quality Assurance A
– Food Safety A (Hygiene and Sanitation A)

FDF 98

FDF 98
FDF Operate a scratch and sizing process

FMSS2 A
Descriptor This is a specialist unit that has been developed for the flour milling
sector. It involves the operation of a separation process which ensure
as little bran as possible ends up with the remaining endosperm.
Range of variables
– Work is carried out in accordance with company procedures, licensing requirements, legislative
requirements and industrial arrangements
– Workplace information can include Standard Operating Procedures (SOPs), specifications and
production schedules
– Equipment used in the scratch and sizing process may include reduction rolls, plansifters,
purifiers, flake disruptors, detachers, mechanical/pneumatic stock transfer equipment
– Confirming equipment status involves checking that hygiene and sanitation standards are met, all
safety guards are in place and equipment is operational
– Stock for the scratch and sizing is supplied from the scalping and grading process
– Services may include power, vacuum and compressed and instrumentation air
– Monitoring the process may involve the use of production data such as performance control
charts
– Process operation and monitoring functions may be manual or involve the use of a process
control system
– Control points refer to those key points in a work process which must be monitored and controlled
This includes food safety (critical) quality and regulatory control points as well as inspection points
– Information systems may be print or screen based
Prepare the scratch and Stock is confirmed and Part A of the Evidence guide identifies the skills and
sizing process for available to meet knowledge to be demonstrated to confirm competence
operation production requirements for this unit. Part B of the Evidence guide outlines how
this guide is to be applied. Both parts should be read
Services are confirmed as
in conjunction with the Range of variables.
being available for
operation Demonstrated ability to:
Equipment is checked to production requirements for the scratch and sizing
confirm readiness for use process
The scratch and size – select, fit and use personal protective clothing and
process is set to meet equipment
production requirements – confirm supply of necessary materials and
services to the scratch and sizing process
– confirm equipment status and condition
– set up and start up the process. This can involve
the use of process control systems
– monitor the scratch and sizing process and
equipment operation to identify out-of-
specification results or non-compliance (cont.)

FDF 98

Operate and monitor The scratch and size Demonstrated ability to: (continued)
the scratch and sizing process is started up – monitor supply and flow of stock to and from the
process according to company scratch and sizing process
procedures – transfer stock to designated location
Control points are – take corrective action in response to out-of
monitored to confirm that specification results or non-compliance
performance is – report and/or record corrective action as required
maintained within – sort, collect, treat, recycle or dispose of waste
specification
– shut down scratch and sizing equipment in
Equipment is monitored to response to an emergency situation
confirm operating – shut down scratch and sizing equipment in
condition response to routine shutdown requirements
Particle size and quantity – prepare scratch and sizing equipment for cleaning
of stock meet – maintain work area to meet housekeeping
specifications standards
Stock flow to and from the – record workplace information
scratch and sizing
process is maintained May include the ability to:
within production – clean and sanitise equipment
requirements – take samples and conduct tests
Out-of-specification – carry out routine maintenance
product, process and
equipment performance is Underpinning knowledge:
identified, rectified and/or – purpose and basic principles the scratch and
reported sizing process
– relationship between the scratch and sizing
Shut down the scratch Scratch and sizing process and other flour milling processes
and sizing process process is shut down – stages and changes which occur during scratch
according company and sizing
procedures – effect of scratch and sizing process on the end
Waste generated by both product
the process and cleaning – quality characteristics to be achieved
procedures is collected, – process specifications, procedures and operating
treated and disposed or parameters
recycled according to – equipment and instrumentation components,
company procedures purpose and operation
– significance and methods of monitoring control
points within the scratch and sizing process
Record information Workplace information is – services used in the scratch and sizing process
recorded in appropriate – common causes of variation and corrective action
format required
– OHS hazards and controls
– 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
– waste handling requirements and procedures
– recording requirements and procedures
May include:
– cleaning and sanitation procedures
– sampling and testing procedures
– routine maintenance procedures

FDF 98

Assessment guide
• Assessment must take into account the food industry’s endorsed assessment guidelines and may use
June 1995.
• The competencies described in this unit need to be performed over time and events under normal
workplace conditions, giving due regard for the key assessment principles of validity, reliability,
fairness and flexibility.
assessee can consistently achieve the workplace outcomes described in the Performance criteria,
including demonstration of the underpinning knowledge and skills contained in the Evidence guide.
• The procedures and documentation should be that actually used in a workplace. Compliance with
statutory OHS, hygiene and sanitation and environmental provisions relevant to the food processing
industry should be emphasised.
context.
competencies for the particular AQF level with this unit.
Assessment context
Assessment of this unit must occur in a real or simulated workplace. Such an environment must
provide an opportunity for the assessee to operate a scratch and sizing process given:
work procedures including advice on safe work practices, food safety and environmental
requirements
– production schedule, batch instructions
– material data safety sheets where appropriate
– specifications, control points and processing parameters
– scratch and sizing equipment
– services as required
– stock required for the scratch and sizing process
– stock flow system
– related work areas and communication system
– relevant OHS clothing and equipment
– routine preventative maintenance schedule as required
– cleaning schedule as required
– sampling and testing schedules as required
– documentation and recording requirements and procedures

Pre-requisites (or equivalent):
Apply basic food safety practices
Apply basic mathematical concepts
Apply basic quality assurance practices
Communicate in the workplace
Apply safe work procedures

FDF 98
Co-requisites:
Implement occupational health and safety principles and procedures
Collect, present and apply workplace information
Implement the food safety plan
Implement the quality system
Operate a grain cleaning process
Operate a wheat break process
Operate a scalping and grading process
Related units:
Clean and sanitise equipment
Apply sampling techniques
Conduct routine tests
Conduct routine preventative maintenance
Where related units form an integral part of operating a scratch and sizing process in the workplace,
these units should be co-assessed.

Main learning resource:
Scratch and Sizing Systems
Cleaning and Sanitation
Food Safety B [Hygiene and Sanitation B and C)
Industrial Communication B
Occupational Health and Safety B
Quality Assurance B
Screenroom Operations
Stock Scalping and Grading
Wheat Break System

FDF 98
FDF FMSG2 A
sector. It involves the separation of the break stock (chop) into
appropriate flows to the next break, purifiers and sizing rolls.
Range of variables
– Scalping and grading equipment includes plansifters and accessories, mechanical/pneumatic
stock transfer equipment. Supporting systems may include compressors, aspirators and filtrators
– Stock for the scalping and grading process is supplied from the scalping and grading process
charts
control system
– Control points refer to those key points in a work process which must be monitored and
controlled. This includes food safety (critical) quality and regulatory control points as well as
inspection points

Prepare the Stock is confirmed and Part A of the Evidence guide identifies the skills and
scalping and available to meet production knowledge to be demonstrated to confirm competence
grading process requirements for this unit. Part B of the Evidence guide outlines how
for operation this guide is to be applied. Both parts should be read in
conjunction with the Range of variables.
being ready for operation
Equipment is checked to Demonstrated ability to:
confirm readiness for use – access workplace information to identify production
requirements for the scalping and grading process
The scalping and grading
– select, fit and use personal protective clothing and
process is set to meet
production requirements equipment
– confirm supply of necessary materials and services
to the scalping and grading process
– monitor the scalping and grading process and
equipment operation to identify out-of-specification
results or non-compliance (cont.)

FDF 98

Operate and The scalping and grading Demonstrated ability to: (cont.)
monitor the process is started up to – monitor supply and flow of materials to and from
scalping and company procedures the scalping and grading process
grading process – take corrective action in response to out-of
Control points are monitored
to confirm that performance specification results or non-compliance
is maintained within – adjust and clean screens
specification – report and/or record corrective action as required
– sort, collect, treat, recycle or dispose of waste
Equipment is monitored to
confirm operating condition – shut down scalping and grading equipment in
response to an emergency situation
Particle size of stock meets – shut down scalping and grading equipment in
specifications response to routine shutdown requirements
Stock flow to and from – prepare scalping and grading equipment for
scalping and grading cleaning
process is maintained within – maintain work area to meet housekeeping
production requirements standards
– record workplace information
Out-of-specification product,
process and equipment
performance is identified, May include the ability to:
rectified and/or reported – clean and sanitise equipment
– take samples and conduct tests
– carry out routine maintenance
Shut down the Scalping and grading
scalping and process is shut down Underpinning knowledge:
grading process according to company – purpose and basic principles the scalping and
procedures grading process
– relationship between the scalping and grading
Waste generated by both the
process and other flour milling processes
process and cleaning
procedures is collected, – stages and changes which occur during scalping
treated and disposed or and grading
recycled according to – effect of scalping and grading process on end
company procedures product
– quality characteristics to be achieved
– process specifications, procedures and operating
Record information Workplace information is parameters
recorded in appropriate – equipment and instrumentation components,
format purpose and operation
points within the scalping and grading process
– services used in the scalping and grading process
– common causes of variation and corrective action
required
problems
May include:

FDF 98

Assessment guide
June 1995.
context.
Assessment context
provide an opportunity for the assessee to operate a scalping and grading process given:
requirements
– scalping and grading equipment
– stock required for the scalping and grading process


FDF 98
Co-requisites:
– Implement occupational health and safety principles and procedures
– Collect, present and apply workplace information
– Implement the food safety plan
– Implement the quality system
– Operate a grain cleaning process
– Operate a wheat break process
Related units:
– Clean and sanitise equipment
– Apply sampling techniques
– Conduct routine tests
– Conduct routine preventative maintenance
Where related units form an integral part of operating a scalping and grading process in the
workplace, these units should be co-assessed.

– Stock Scalping and Grading
– Cleaning and Sanitation
– Food Safety B (Hygiene and Sanitation B and C)
– Industrial Communication B
– Occupational Health and Safety B
– Quality Assurance B
– Screenroom Operation
– Wheat Break System

FDF 98
Operate a reduction process
FDF FMRP2 A
sector. It involves grinding and sifting endosperm particles to gradually
reduce their size to meet specifications
Range of variables
– Reduction equipment may include reduction rolls, plansifters, impactors, entoleters (flake
disruptors and detachers)
– Stock for the reduction is supplied from either the scalping and grading or scratch and sizing or
purification processes
– By-products (co-products) may include semolina, sharps
charts
control system
inspection points
Prepare the reduction Stock is confirmed and Part A of the Evidence guide identifies the skills and
process for operation available to meet knowledge to be demonstrated to confirm competence
production requirements for this unit. Part B of the Evidence guide outlines how
this guide is to be applied. Both parts should be read
in conjunction with the Range of variables.
being ready for reduction
operation Demonstrated ability to:
Equipment is checked to – access workplace information to identify
confirm readiness for use production requirements for the reduction process
The reduction process is – select, fit and use personal protective clothing and
set to meet production equipment
requirements – confirm supply of necessary materials and
services to the reduction process
– monitor the reduction process and equipment
operation to identify out-of-specification results or
non-compliance (cont.)

FDF 98

Operate and monitor Reduction process is Demonstrated ability to: (continued)
the reduction process started up according to – monitor supply and flow of materials to and from
company procedures the reduction process
performance is maintained – report and/or record corrective action as required
within specification – sort, collect, treat, recycle or dispose of waste
Equipment is monitored to – shut down reduction equipment in response to an
confirm operating condition emergency situation
– shut down wheat break equipment in response to
Particle size meets
routine shutdown requirements
specifications
– prepare reduction equipment for cleaning
Flour extraction rates meet – maintain work area to meet housekeeping
production specifications standards
By-product generated from – record workplace information
the reduction process is
segregated and transferred May include the ability to:
to designated storage area – clean and sanitise equipment
according to food safety – take samples and conduct tests
requirements – carry out routine maintenance
Out-of-specification
equipment – purpose and basic principles the reduction process
performance is – relationship between the reduction process and
identified, rectified other flour milling processes
and/or reported – stages and changes which occur during reduction
– effect of reduction process on the end product
Shut down the reduction Reduction process is shut – quality characteristics to be achieved
process down according to – process specifications, procedures and operating
company procedures parameters
Waste generated by both – equipment and instrumentation components,
the process and cleaning purpose and operation
procedures is collected, – significance and methods of monitoring control
treated and disposed or points within the reduction process
recycled according to – services used in the reduction process
company procedures
– common causes of variation and corrective action
required
Record information Workplace information – OHS hazards and controls
is recorded in – lock out and tag out procedures
appropriate format – procedures and responsibility for reporting
problems
May include:

FDF 98

Assessment guide
June 1995.
context.
Assessment context
provide an opportunity for the assessee to operate a reduction process given:
requirements
– production schedule
– reduction equipment
– stock required for the reduction process


FDF 98
Co-requisites:
– Operate a grain screening process
– Operate a scalping and grading process
– Operate a scratch and sizing process
– Operate a purification process
Related units:
Where related units form an integral part of operating a reduction process in the workplace, these
units should be co-assessed.

– Reduction System
– Scratch and Sizing Systems
– Screenroom Operations
– Scratch and Sizing systems
– Stock Purification

FDF 98
Operate a grain receival process
FDF ZZGR2 A
Descriptor This is a specialist unit that has been developed for both the flour
milling and petfood sectors. It involves handling the grain intake
through a silo system, testing and conditioning grain and maintaining
an infestation free storage and work area.
Range of variables
– The grain receival equipment may include weighbridge, mechanical/pneumatic stock transfer
equipment, magnets, weighers, grain cleaning equipment, sampling and testing equipment (for
example, balance, moisture meter, infra analyser, chronometer, sieves)
charts
control system
inspection points
– Pest control and pesticide treatment will be handled by people with the appropriate government
licence
– Infestation may include insects, rodents, birds
Prepare the grain Materials are confirmed Part A of the Evidence guide identifies the skills
receival process for and available to meet and knowledge to be demonstrated to confirm
operation production requirements competence for this unit. Part B of the Evidence
guide outlines how this guide is to be applied.
Both parts should be read in conjunction with the
Range of variables.
Equipment is checked to
confirm readiness for use Demonstrated ability to:
The grain receival process requirements for the grain receival process
is set to meet intake
– select, fit and use personal protective
requirements
clothing and equipment
– confirm supply of necessary materials and
services to the grain receival process
– set up and start up the process. This can
involve the use of process control systems
(cont.)

FDF 98

Operate and monitor The grain receival process Demonstrated ability to: (continued)
the grain receival is started up to company – monitor the grain receival process and
process procedures equipment operation to identify out-of-
Control points are specification results or non-compliance.
monitored to confirm that – collect samples and conducts in-process
performance is maintained tests to monitor product quality
within specification – identify/report infestation, illegal seeds
Equipment is monitored to – monitor supply and flow of materials to and
confirm operating condition from the grain receival process
– take corrective action in response to out-of
Incoming grain is sampled, specification results or non-compliance
tested and directed to silos
– report and/or record corrective action as
according to food safety
required
and storage requirements
– sort, collect, treat, recycle or dispose of
Infestation is identified and waste
action taken for its removal – shut down grain receival equipment in
from the grain receival area response to an emergency situation
according to pest control
– shut down grain receival equipment in
requirements
response to routine shutdown requirements
Stock flow to and from – prepare grain receival equipment for
grain receival process is cleaning
maintained within – maintain work area to meet housekeeping
production requirements standards
Out-of-specification – record workplace information
equipment performance is May include the ability to:
identified, rectified and/or – clean and sanitise equipment
reported – carry out routine maintenance
Waste generated by the
grain receival process is Underpinning knowledge:
monitored and cleared – purpose and basic principles the grain
according to company receival process
procedures
– principles of operation of the silo system
– relationship between the grain receival
process and other flour milling processes
Shut down the grain Grain receival process is
receival process shut down according to – stages and changes which occur during
company procedures grain receival
– effect of grain receival process on the end
Waste generated by both product
the process and cleaning
– types of grain and their quality parameters
procedures is collected,
treated and disposed or – quality characteristics to be achieved
recycled according to – process specifications, procedures and
company procedures operating parameters
– equipment and instrumentation components,
purpose and operation
Record information Workplace information is – significance and methods of monitoring
recorded in appropriate control points within the grain receival
format process
– services used in the grain receival process
– common causes of variation and corrective
action required (cont.)

FDF 98

– pest control and pesticide treatment
responsibilities
problems
– shutdown and cleaning requirements
associated with changeovers and types of
shutdowns
– waste handling requirements and
procedures
May include:

Assessment guide
• Assessment must take into account the food and beverage industry’s endorsed assessment guidelines
and may use the non-endorsed Assessment Framework for the Food and Beverage Processing
Industry NFITC June 1995.
including demonstration of the underpinning knowledge and skills contained in the Evidence guide
context.
Assessment context
provide an opportunity for the assessee to operate a grain receival process given:
requirements
– production schedule
– grain receival equipment

FDF 98
– stock in the grain receival process
– sampling and testing schedules
– Australian Wheat Board standards
– wheat identification charts

Co-requisites:
– Operate a grain conditioning process
Related units:
Where related units form an integral part of a grain receival process in the workplace, these units
should be co-assessed.

– Parts of Materials Handling A, B and C
– Stockfeed Raw Materials Handling

FDF 98

FDF 98
Operate a flour blending process
FDF ZZFB2 A
sector. It involves combining flours into a new finished product.
Range of variables
– Blending equipment may include blenders, sieves, weighing equipment, mechanical/pneumatic
stock transfer equipment
– Stock used in blending includes flours, vitamins, bleach
charts
control system
inspection points
Prepare the blending Stock is confirmed and Part A of the Evidence guide identifies the skills and
process for operation available to meet knowledge to be demonstrated to confirm
production requirements competence for this unit. Part B of the Evidence
guide outlines how this guide is to be applied. Both
parts should be read in conjunction with the Range
of variables.
Equipment is checked to Demonstrated ability to:
confirm readiness for use
The bending process is set production requirements for the blending
to meet production process
requirements – select, fit and use personal protective clothing
and equipment
services to the blending process
– monitor the blending process and equipment
operation to identify out-of-specification results
or non-compliance. This can involve adjusting
flow rates
– monitor supply and flow of materials to and from
the blending process (cont.)

FDF 98

Operate and monitor The blending process is Demonstrated ability to: (continued)
the blending process started up according to – take corrective action in response to out-of
company procedures specification results or non-compliance
Control points are – report and/or record corrective action as
monitored to confirm that required
performance is maintained – sort, collect, treat, recycle or dispose of waste
within specifications – shut down blending equipment in response to
an emergency situation
Equipment is monitored to – shut down blending equipment in response to
confirm operating condition routine shutdown requirements
Blended product meets – prepare blending equipment for cleaning
specifications – maintain work area to meet housekeeping
standards
Blended product is stored – record workplace information
according to food safety May include the ability to:
requirements – clean and sanitise equipment
Stock flow to and from – take samples and conduct tests
blending process is – carry out routine maintenance
maintained within
production requirements Underpinning knowledge:
– purpose and basic principles the blending
process
– relationship between the blending process and
equipment performance is
other flour milling processes
identified, rectified and/or
– stages and changes which occur during
reported
blending
– types of additives and ingredients
– effect of blending process on end product
Shut down the blending Blending process is shut – quality characteristics to be achieved
process down according to – legislative requirements in blending flour
procedures products
Waste generated by both – microbiological considerations in mixing flours
the process and cleaning – process specifications, procedures and
procedures is collected, operating parameters
treated and disposed or – equipment and instrumentation components,
recycled according to purpose and operation
company procedures – significance and methods of monitoring control
– points within the blending process
– services used in the blending process
Record information Workplace information – common causes of variation and corrective
action required
is recorded in the
appropriate format – lock out and tag out procedures
problems
shutdowns
May include:

FDF 98

Assessment guide
June 1995.
context.
Assessment context
provide an opportunity for the assessee to operate a blending process given:
requirements
– production schedule, batch/recipe instructions
– blending equipment
– stock required for the blending process


FDF 98
Co-requisites:
Related units:
Where related units form an integral part of operating a blending process in the workplace, these
units should be co-assessed

– Flour Pre-Mixing and Blending

FDF 98
Operate a purification process
FDF FMPP2 A
sector. It covers a separation and grading process which involves a
combination of sieving, shaking, gravity and aspiration to remove any
particles of bran, with or without endosperm or germ attached, from
the stock flow
Range of variables
– Equipment used in the purification process is a series of purifiers with related dust and collection
systems, mechanical/pneumatic stock transfer equipment -
– Stock for purification is supplied from either the scratch and sizing process
charts
control system
inspection points
Prepare the purification Stock is confirmed and Part A of the Evidence guide identifies the skills
process for operation available to meet and knowledge to be demonstrated to confirm
production requirements competence for this unit. Part B of the Evidence
Range of variables.
Demonstrated ability to:
confirm readiness for use
The purification process is production requirements for the purification
set to meet production process
requirements – select, fit and use personal protective
services to the purification process
– monitor the purification process and
equipment operation to identify (cont.)

FDF 98

Operate and monitor The purification process is Demonstrated ability to: (continued)
the purification process started up according to – out-of-specification results or non-
company procedures compliance. This can include the need to
Control points are make adjustments to stock flow, feed gates
monitored to confirm that and screens
performance is maintained – monitor supply and flow of materials to and
within specification from the purification process
– take corrective action in response to out-of
specification results or non-compliance
confirm operating condition
Particle size and quantity of required
stock meets specifications – sort, collect, treat, recycle or dispose of
Fine bran is removed from waste
the semolina and the bran – shut down purification equipment in
product with endosperm response to an emergency situation
attached is returned to the – shut down purification equipment in
purification process or response to routine shutdown requirements
scratch rolls for further – prepare purification equipment for cleaning
processing
– maintain work area to meet housekeeping
Stock flow to and from standards
purification process is – record workplace information
maintained within May include the ability to:
production requirements
– clean and sanitise equipment
Out-of-specification – take samples and conduct tests
product, process and – carry out routine maintenance
equipment performance is
reported Underpinning knowledge:
– purpose and basic principles the purification
process
Shut down the Purification process is shut – relationship between the purification process
purification process down according to and other flour milling processes
company procedures – stages and changes which occur during
Waste generated by both purification
the process and cleaning – effect of purification process on the end
procedures is collected, product
treated and disposed or – quality characteristics to be achieved
recycled according to – process specifications, procedures and
Record information Workplace information is – equipment and instrumentation components,
recorded in appropriate – purpose and operation
format – significance and methods of monitoring
control points within the purification process
– services used in the purification process -
common causes of variation and corrective
action required
problems
– environmental issues and controls (cont.)

FDF 98

shutdowns
procedures
May include:

Assessment guide
• Assessment must take into account the food industry’s endorsed assessment and the Assessment
Framework for the Food and Beverage Processing Industry NFITC June 1995.
context.
Assessment context
provide an opportunity for the assessee to operate a purification process given:
requirements
– purification equipment
– stock required for the purification process
FDF 98


Co-requisites:
– Operate a scalping and grading process
– Operate a scratch and sizing process
Related units:
Where related units form an integral part of operating a purification process in the workplace, these

Main learning resources:
– Purification
– Scratch and Sizing Systems

FDF 98
Operate a flour pre-mix process
FDF ZZPM2 A
Descriptor This is a specialist unit that has been developed for both the flour
milling and petfood sectors. It involves operating a pre-mix process to
combine additives and raw materials/ingredients to create a product
for internal or external customers.
Range of variables
– Pre-mix equipment may include mixers, sieves, weighing equipment, mechanical/pneumatic stock
transfer equipment
– Materials used in pre-mix may include additives, ingredients
charts
control system
inspection points
Prepare the pre-mix Materials are confirmed Part A of the Evidence guide identifies the
process for operation and available to meet skills and knowledge to be demonstrated to
production requirements confirm competence for this unit. Part B of
the Evidence guide outlines how this guide is
to be applied. Both parts should be read in
conjunction with the Range of variables.
The pre-mix process is production requirements for the pre-mix
requirements – select, fit and use personal protective
– confirm supply of necessary materials
and services to the pre-mix process
involve the use of process control
systems (cont.)

FDF 98

Operate and monitor The pre-mix process is Demonstrated ability to: (continued)
the pre-mix process started up according top – monitor the pre-mix process and
company specifications equipment operation to identify out-of-
Control points are specification results or non-compliance
monitored to confirm that – monitor supply and flow of materials to
performance is maintained and from the pre-mix process
within specification – take corrective action in response to out-
of specification results or non-
compliance.
confirm operating condition
Pre-mixed product meets required
specifications – conduct product/batch changeover
Pre-mixed product is stored – sort, collect, treat, recycle or dispose of
according to food safety waste
requirements – shut down pre-mix equipment in
Stock flow to and from pre- response to an emergency situation
mix process is maintained – shut down pre-mix equipment in
within production response to routine shutdown
requirements requirements
– prepare pre-mix equipment for cleaning
product, process and – maintain work area to meet
equipment performance is housekeeping standards
identified, rectified and/or – record workplace information
reported
May include the ability to:
Waste generated by the – clean and sanitise equipment
process is monitored and – take samples and conduct tests
cleared according to – carry out routine maintenance
company procedures
Shut down the pre-mix Pre-mix process is shut
process down according to – purpose and basic principles the pre-mix
company procedures process
– relationship between the pre-mix process
Waste generated by both and other flour milling processes
the process and cleaning – stages and changes which occur during
procedures is collected, pre-mixing
treated and disposed or
recycled according to – types of additives and ingredients
company procedures – legislative requirements in mixing flour
products
– microbiological considerations in mixing
additives and ingredients
Recording information Workplace information is – effect of pre-mix process on end product
recorded in the appropriate – quality characteristics to be achieved
format
– purpose of the break rolls
– how and why the separation of
endosperm takes place
– process specifications, procedures and
operating parameters
– equipment and instrumentation
components, purpose and operation
– significance and methods of monitoring
control points within the pre-mix process
(cont.)

FDF 98

– services used in the pre-mix process
– common causes of variation and
corrective action required
– procedures and responsibility for
reporting problems
associated with changeovers and types
of shutdowns
procedures
May include:

Assessment guide
context.
Assessment context
provide an opportunity for the assessee to operate a pre-mix process given:
requirements
– production schedule, batch/recipe instructions

FDF 98

– pre-mix equipment
– stock required for the pre-mix process

Co-requisites:
Related units:
Where related units form an integral part of operating a flour pre-mix process in the workplace, these
units should be co-assessed

– Flour Pre-mix and Blending

FDF 98
Operate a grain conditioning process
FDF FMCO2 A
sector. It involves adding water to the grain to create a moisture level
which assists the separation and reduction processes.
Range of variables
– Conditioning equipment may include conditioning bins, mechanical/pneumatic stock transfer
equipment, automatic water addition equipment
– Stock for the conditioning process may be clean grain direct from the silo or cleaned wheat from
the cleaning process
charts
control system
inspection points

Prepare the Stock is confirmed and Part A of the Evidence guide identifies the skills and
conditioning process available to meet knowledge to be demonstrated to confirm
for operation production requirements competence for this unit. Part B of the Evidence
of variables.
The conditioning system is production requirements for the conditioning
requirements
– select, fit and use personal protective clothing
and equipment
services to the conditioning process
– monitor the conditioning process and equipment
operation to identify out-of-specification results
or non-compliance (cont.)

FDF 98

Operate and monitor The conditioning process is Demonstrated ability to: (continued)
the conditioning started up according to – monitor supply and flow of materials to and from
process company procedures the conditioning process
performance is maintained – report and/or record corrective action as required
within specification – sort, collect, treat, recycle or dispose of waste
Equipment is monitored to – shut down conditioning equipment in response to
confirm operating condition an emergency situation
– shut down conditioning equipment in response to
Conditioned product meets
routine shutdown requirements
grist moisture specifications
– prepare conditioning equipment for cleaning
Conditioned product is – maintain work area to meet housekeeping
stored according to food standards
safety requirements
– record workplace information
Stock flow to and from
conditioning process is May include the ability to:
maintained within – clean and sanitise equipment
production requirements – take samples and conduct tests
equipment performance is Underpinning knowledge:
identified, rectified and/or – purpose and basic principles the conditioning
reported process
– relationship between the conditioning process
Shut down the Conditioning process is and other flour milling processes
conditioning process shut down according to – stages and changes which occur during
company procedures conditioning
Waste generated by both – types of grain and their qualities
the process and cleaning – microbiological considerations in conditioning
procedures is collected, grain
treated and disposed or – effect of conditioning process on the end product
recycled according to – quality characteristics to be achieved
company procedures – process specifications, procedures and operating
parameters
– equipment and instrumentation components,
purpose and operation
Record information Workplace information – significance and methods of monitoring control
is recorded in the – points within the conditioning process
appropriate format – services used in the conditioning process
action required
problems
– recording requirements and procedures (cont.)

FDF 98

May include:

Assessment guide
context.
Assessment context
provide an opportunity for the assessee to operate a conditioning process given:
requirements
– conditioning equipment
– stock required for the conditioning process

FDF 98

Co-requisites:
Related units:
Where related units form an integral part of operating a conditioning process in the workplace, these

– Screenroom Operations

FDF 98
FDF FMGC2 A
sector. It involves screening impurities from the grist prior to the
conditioning process.
Range of variables
The range of variables provides further advice to interpret the scope and scale of this unit of
– Grain cleaning equipment may include intake equipment, day bins, separators, aspirators,
extractors/destoners, scourers, scales, dampers, measurers/mixers, hammer mills, impact
grinders, materials handling equipment
– Raw materials for grain cleaning may include grist previously cleaned or dirty wheat which has
been accepted by the mill
charts
control system
inspection points
Prepare the grain Stock is confirmed and Part A of the Evidence guide identifies the skills
cleaning process for available to meet production and knowledge to be demonstrated to confirm
operation requirements competence for this unit. Part B of the Evidence
Both parts should be read in conjunction with
the Range of variables.
The bin system is set-up to production requirements for the grain
meet production cleaning process
requirements
– select, fit and use personal protective
services to the grain cleaning process
(cont.)

FDF 98
Evidence Performance criteria Evidence guide – Part A

Operate and monitor the The grain cleaning process Demonstrated ability to: (continued)
grain cleaning process is started up according to – monitor the grain cleaning process and
company procedures equipment operation to identify out-of-
Control points are specification results or non-compliance
monitored to confirm that – monitor supply and flow of materials to and
performance is maintained from the grain cleaning process
within specifications – take corrective action in response to out-of
specification results or non-compliance
confirm operating condition – report and/or record corrective action as
required
Stock meets grist – sort, collect, treat, recycle or dispose of
specifications waste
Impurity removal rate meets – shut down grain cleaning equipment in
specifications response to an emergency situation
Stock flow to and from the – shut down grain cleaning equipment in
graining cleaning process is response to routine shutdown requirements
maintained within – prepare grain cleaning equipment for
production requirements cleaning
Out-of-specification product,
standards
process and equipment
performance is identified, – record workplace information
rectified and/or reported May include the ability to:
Waste generated by the – clean and sanitise equipment
process is monitored and – take samples and conduct tests
cleared according to – carry out routine maintenance
company procedures
Shut down the grain Grain cleaning process is – purpose and basic principles the grain
cleaning process shut down according to cleaning process
company procedures – relationship between the grain cleaning
Waste generated by both process and other flour milling processes
the process and cleaning – stages and changes which occur during
procedures is collected, grain cleaning
treated and disposed or – how and why various kinds of wheat are
recycled according to blended to make grist
company procedures – common impurities found in the grain
cleaning process
– effect of grain cleaning process on the end
Record information Workplace information is product
recorded in the appropriate
– quality characteristics to be achieved
format
– how and why the separation of endosperm
takes place
– process specifications, procedures and
operating parameters
– equipment and instrumentation
components, purpose and operation
– significance and methods of monitoring
control points within the grain cleaning
process (cont.)

FDF 98
Evidence Performance criteria Evidence guide – Part A

– services used in the grain cleaning process
action required
problems
shutdowns
procedures
May include:

Assessment guide
June 1995.
workplace conditions, having due regard for the key assessment principles of validity, reliability,
• The procedures and documentation should by those typically used in a workplace. Compliance with
occupational health and safety, food safety, hygiene and environmental requirements relevant to the
food processing industry should be emphasised.
context.
• Assessment should not require a higher level of communication competency than the food industry’s
Assessment context
provide an opportunity for the assessee to operate a grain cleaning process given:
requirements

FDF 98
– grain cleaning equipment

– stock required for the grain cleaning process

Co-requisites:
Related units:
Where related units form an integral part of operating a grain cleaning process in the workplace,
these units should be co-assessed.



FDF 98
Operate a wheat break process

FDF FMWB2 A
sector. It involves separating bran from the endosperm.
Range of variables
– Wheat break equipment may include break rolls (roller mills), mechanical/pneumatic stock transfer
equipment, bran finishers, dressing machines
– Grain for the wheat break process is supplied from the cleaning and conditioning processes
– By-products may include wheat germ, pollard, bran, semolina
– Monitoring the process may involve the use of production data such as performance control charts
– Process operation and monitoring functions may be manual or involve the use of a process control
system
– Control points refer to those key points in a work process which must be monitored and controlled.
This includes food safety (critical) quality and regulatory control points as well as inspection points
Prepare the wheat Stock is confirmed and Part A of the Evidence guide identifies the skills
break process for available to meet and knowledge to be demonstrated to confirm
operation production requirements competence for this unit. Part B of the Evidence
of variables.
The wheat break process is production requirements for the wheat break
requirements
– select, fit and use personal protective clothing
and equipment
services to the wheat break process
– monitor the wheat break process and
equipment operation to identify out-of-
specification results or non-compliance. This
can involve monitoring bran separation (cont.)
© Australian National Training Authority li

FDF 98

Operate and monitor The wheat break process is Demonstrated ability to: (continued)
the wheat break started up to company – monitor supply and flow of materials to and
process procedures from the wheat break process
performance is maintained – report and/or record corrective action as
within specifications required
– sort, collect, treat, recycle or dispose of waste
Equipment is monitored to – shut down wheat break equipment in response
confirm operating condition to an emergency situation
Bran separated from – shut down wheat break equipment in response
endosperm meets to routine shutdown requirements
specifications – prepare wheat break equipment for cleaning
By-product generated from
standards
the wheat break process is
segregated and transferred – record workplace information
to designated location May include the ability to:
– clean and sanitise equipment
Stock flow to and from – take samples and conduct tests
wheat break process is
maintained within
production requirements
Out-of-specification – purpose and basic principles the wheat break
product, process and process
equipment performance is – relationship between the wheat break process
identified, rectified and/or and other flour milling processes
reported
– stages and changes which occur during wheat
break
– effect of wheat break process on the end
Shut down the wheat Wheat break process is
product
break process shut down according to
company procedures – quality characteristics to be achieved
Waste generated by both – how and why the separation of endosperm
the process and cleaning takes place
procedures is collected, – process specifications, procedures and
treated and disposed or operating parameters
recycled according to – equipment and instrumentation components,
company procedures purpose and operation
points within the wheat break process
Record information Workplace information – services used in the wheat break process
is recorded in the – common causes of variation and corrective
company reporting action required
system – OHS hazards and controls
problems
shutdowns
– recording requirements and procedures (cont.)
lii © Australian National Training Authority

FDF 98

Underpinning knowledge: (cont.)
May include:

Assessment guide
• Assessment must take into account the food industry’s endorsed assessment guidelines and may use the
non-endorsed Assessment Framework for the Food and Beverage Processing Industry NFITC June
1995.
workplace conditions, giving due regard for the key assessment principles of validity, reliability, fairness
and flexibility.
context.
Assessment context
Assessment of this unit must occur in a real or simulated workplace. Such an environment must provide
an opportunity for the assessee to operate a wheat break process given:
requirements
– wheat break equipment
– stock required for the wheat break process
– sampling testing schedules as required
© Australian National Training Authority liii

FDF 98

Co-requisites:
Related units:
Where related units form an integral part of operating a wheat break process in the workplace, these

liv © Australian National Training Authority

FDF 98
© Australian National Training Authority lv

FDF 98
Operate a system (Flour Milling)

FDF FMOS3 A
Descriptor This is a specialist unit that has been customised for the flour
milling sector. It covers the preparation and operation of a
production or packaging system.
A system typically describes the operation of an entire process
which may comprise a number of sub-systems. System operation
requires higher level planning and problem solving skills than are
necessary when operating an individual sub-system or piece of
equipment. It can also involve facilitating the work of others.
Range of variables
requirements and industrial awards and agreements
– System operation typically involves planning, co-ordination and troubleshooting within their level of
authority
– Flour milling equipment will depend on the milling system and may typically include intake equipment,
separators, sieves, aspirators, extractors/destoners, scourers, dampers, measurers/mixers, hammer
mills, grinders, break rolls (roller mills), vibrodusters, bran finishers, dressing machines, plansifters,
purifiers, reduction rolls, scratch rolls, entoleters (flake disruptors and detachers),
mechanical/pneumatic stock transfer equipment
– Control points refer to those key points in a work process which must be monitored and controlled.
This includes food safety (critical), quality and regulatory control points as well as inspection points
– Co-ordination, planning and troubleshooting is undertaken with assistance from others
– Workplace systems are in place to support production/packaging processes. These include quality,
food safety, occupational health and safety and environmental management

Prepare the system for Supply of materials is Part A of the Evidence guide identifies the skills
operation confirmed to meet and knowledge to be demonstrated to confirm
production/packaging competence for this unit. Part B of the Evidence
requirements guide outlines how this guide is to be applied.
Work area is prepared for
Range of variables.
operation
Services are confirmed as Demonstrated ability to:
available and ready for – liaise with relevant work areas to confirm or
operation secure necessary materials, services,
equipment and labour to meet
Equipment and work area production/packaging requirements
is checked to confirm
readiness for use – confirm that all equipment within the system
meets hygiene and sanitation standards, all
The system is set to meet safety guards are in place and equipment is
specifications ready for operation (cont.)
lvi © Australian National Training Authority

FDF 98
Element Performance criteria Evidence guide –Part A

Operate and monitor The system is started up Demonstrated ability to: (continued)
the system according to company – monitor implementation of set up and start up
procedures procedures. This may involve monitoring the
Control points are use of checksheets by others
monitored to confirm – monitor observance of work procedures and
performance is maintained systems
within specification – monitor materials flow and work-in-progress
System outputs meet through the system
specification – confirm that the system operates within
specified parameters and control points are
Equipment is monitored to monitored
confirm operating
– determine responses to out-of-specification
condition
results or non-conformance within level of
Out-of-specification responsibility
product, process and – co-ordinate batch/product changeovers
equipment performance is – communicate information effectively
– plan maintenance and cleaning procedures to
reported
minimise disruption
Waste generated by the – monitor operating efficiencies of the system
process is monitored and and investigate, resolve and/or report
cleared as required problems
– review and maintain procedures to support
system improvements
Shut down the system Equipment is shut down
according to company Underpinning knowledge:
procedures – purpose and principles of the pharmaceutical
production/packaging system
Cleaning and sanitising
requirements for – equipment purpose and operation including
equipment and work area an understanding of process control systems
are identified where used
– technical knowledge of product characteristics
Equipment is cleaned and and processing requirements
maintained to meet
– codes and legislation relating to product and
production/packaging and
packaging requirements
hygiene requirements
– equipment calibration schedule and
Waste generated by both responsibilities
the process and cleaning – type and purpose of tests conducted
procedures is collected,
– related work areas and departments
treated and disposed or
recycled according to – relevant procedures, specifications and
– relevant systems and legislative requirements
– responsibilities in areas such as human
Record information Workplace information is
resources, food safety, quality, occupational
recorded and reported in
health and safety and environmental
required format management
– industrial awards and agreements relating to
system operation
– hazards, risks, controls and methods for
monitoring processes within the system
(cont.)
© Australian National Training Authority lvii

FDF 98
Element Performance criteria Evidence guide –Part A

Contribute to Quality of process outputs Underpinning knowledge: (continued)
continuous is assessed against – maintenance and cleaning requirements of
improvement of the specifications equipment in production/packaging system
system
Opportunities for – end of batch procedures
improvement are identified – yield and reconciliation requirements
and investigated – process improvement procedures and related
Proposals for consultative arrangements
improvements are – troubleshooting procedures and problem
developed and solving techniques
implemented within – recording and reporting requirements
company planning
arrangements and
according to company
procedures

Assessment guide
• Assessment must take account of the food industry’s endorsed assessment guidelines and may use the
non-endorsed Assessment Framework for the Food and Flour milling Processing Industry NFITC June
1995.
• The competencies described in this unit need to be performed over time and events, under normal
workplace conditions, having due regard for the key assessment principles of validity, reliability, fairness
and flexibility.
assessee can achieve the workplace outcomes described in the Performance criteria, including
demonstration of the underpinning knowledge and skills contained in the Evidence guide.
context.
• The procedures and documentation should be those typically used in a workplace. Compliance with
statutory occupational health and safety, food safety, hygiene and environmental requirements relevant to
the food processing industry should be emphasised.
competencies for the particular AQF level.
Assessment context
Assessment of this unit must occur in a real or simulated workplace. Such an environment must provide
an opportunity for the assessee to prepare and operate a production or packaging system given:
– work procedures including advice on safe work practices, food safety and environmental requirements
for processes within the production/packaging system
– company policies and workplace systems including human resources, OHS, quality, food safety and
environmental management
– production/packaging schedule, batch instructions
– specifications, control points and processing parameters for processes within the production/
packaging system
– production/packaging system equipment
– personnel operating the production/packaging system
lviii © Australian National Training Authority
FDF 98
– services
– cleaning, calibration and maintenance schedules as required
– troubleshooting advice where available
– documentation and record keeping system
– planning, resources management and training arrangements

Pre-requisites or equivalent:
– Specialist units from AQF 2 (the pre-requisites will depend on the enterprise’s milling processes)
Co-requisites:
– Analyse and convey workplace information
– Monitor the implementation of occupational health and safety
– Monitor the implementation of the quality system
– Monitor the implementation of the food safety plan
Related units:
– Facilitate teams
Where related units form an integral part of system operation in the workplace, these units should be
co-assessed.

– Flour Mill Operation A
– Flour Mill Operation B
– Industrial Communication C
– Quality Assurance C
– Occupational Health and Safety C
– Food Safety C (Hygiene and Sanitation D)
– Work Team Communication
© Australian National Training Authority lix

FDF 98

Flour Operations

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NATIONAL FOOD INDUSTRY

© Australian National Training Authority 5

© Australian National Training Authority

Published by: Australian Training Products Ltd

6 © Australian National Training Authority

INDEX TO: Flour Milling Units

UNIT CODE UNIT TITLE PAGE NO.

FDF FMDC1 A Locate industry and company products and 1

FDF FMSS2 A Operate a scratch and sizing process 5

FDF FMSG2 A Operate a scalping and grading process 9

FDF FMRP2 A Operate a reduction process 13

FDF ZZFR2 A Operate a grain receival process 17

FDF ZZFB2 A Operate a flour blending process 21

FDF FMPP2 A Operate a purification process 25

FDF ZZPM2 A Operate a flour pre-mix process 29

FDF FMCO2 A Operate a grain conditioning process 33

FDF FMGC2 A Operate a grain cleaning process 37

FDF FMWB2 A Operate a wheat break process 41

FDF FMOS3 A Operate a system (Flour Milling) 45

© Australian National Training Authority 7

8 © Australian National Training Authority

Locate industry and company products and

Element Performance criteria Evidence guide – Part A

© Australian National Training Authority 9

Element Performance criteria Evidence guide – Part A

Evidence guide – Part B

Relationship to other units

Relationship to learning resources

10 © Australian National Training Authority

– Introductory Milling B (Flour Milling)

© Australian National Training Authority 11

12 © Australian National Training Authority

FDF Operate a scratch and sizing process

© Australian National Training Authority 13

Element Performance criteria Evidence guide – Part A

14 © Australian National Training Authority

Evidence guide – Part B

Relationship to other units

© Australian National Training Authority 15

Relationship to learning resources

16 © Australian National Training Authority

Element Performance criteria Evidence guide – Part A

© Australian National Training Authority 17

Element Performance criteria Evidence guide – Part A

18 © Australian National Training Authority

Evidence guide – Part B

Relationship to other units

© Australian National Training Authority 19

Relationship to learning resources

20 © Australian National Training Authority

© Australian National Training Authority 21

Element Performance criteria Evidence guide – Part A

22 © Australian National Training Authority

Evidence guide – Part B

Relationship to other units

© Australian National Training Authority 23

Relationship to learning resources

24 © Australian National Training Authority

© Australian National Training Authority 25

Element Performance criteria Evidence guide – Part A

26 © Australian National Training Authority

Element Performance criteria Evidence guide – Part A

Evidence guide – Part B