Process control and machine operators in food and beverage processing operate multi-function process control machinery or single function machines to process and package food and beverage products. They are employed in fruit and vegetable processing plants, dairies, flour mills, bakeries, sugar refineries, meat plants, breweries and other food and beverage processing establishments.

• communication skills
• measurement math
• problem solving.

The typical text reading tasks of process control and machine operators in food and beverage processing are at Complexity Levels 1 to 3. Their most complex text reading tasks are at Complexity Levels 1 to 3.

Process control and machine operators in food and beverage processing may:

• read notes outlining the types and quantities of products to be processed. (1)
• read company rules and regulations. (2)
• read memos from the office regarding production schedules. (frequently) (2)
• read changes in brewing procedures. (2)
• read food handling manuals to stay current on sanitation and hygiene. (3)
• read machine manuals to learn how to care for and repair the processing machines. (3)
• read Material Safety Data Sheets (MSDS) to locate information about the handling and cleanup of spills. (3)

The typical document reading tasks of process control and machine operators in food and beverage processing are at Complexity Levels 1 to 3. Their most complex document reading tasks are at Complexity Levels 1 to 3.

Process control and machine operators in food and beverage processing:

• read safety signs and symbols postedthroughout the plant. (1)
• read product codes for ingredientsand packaging materials. (1)
• read lists of ingredients and recipeformula printouts indicating the amount of ingredients requiredfor batches of different sizes. (daily) (2)
• read graphs to determine if the airlevel in cans is within an acceptable range. (2)
• read computer charts which show whichproducts are running from which tank and at what temperature.(2)
• obtain information from pictures and icons on the computer screen. (2)
• read a schematic diagram of the production process on the computer screen, with a flashing light indicating the part of the process presently in progress. (2)
• read assembly drawings to understand machine cleaning and maintenance functions. (3)

Process control and machine operators in food and beverage processing:

• complete Workplace Hazardous Materials Information System (WHMIS) labels when pouring cleaning chemicals from one container to another.
• complete production record forms by entering codes for weight and taste.
• fill in order forms to obtain ingredients from suppliers.
• record information in tables listing all ingredients used and their weights.
• complete work schedules.
• complete bar graphs to show the efficiency of current hourly production when compared to a standard hourly rate set by the company.
• read pressure and temperature gauges on tanks.

Process control and machine operators in food and beverage processing:

• >>> read signs, labels or lists.
• >>> complete forms by marking check boxes, recording numerical information or entering words, phrases or sentences.
• >>> read completed forms containing check boxes, numerical entries, phrases, addresses or, sometimes, sentences.
• >> read tables, schedules or other table-like text.
• > enter information on tables, schedules or other table-like text.
• > obtain specific information from graphs or charts.
• > read assembly drawings.
• > obtain information from sketches, pictures or icons.

The typical writing tasks of process control and machine operators in food and beverage processing are at Complexity Levels 1 and 2. Their most complex writing tasks are at Complexity Levels 1 and 2.

Process control and machine operators in food and beverage processing:

• write reminder notes and "to do" lists for the incoming shift. (daily) (1)
• write memos to the maintenance department to request repairs. (1)
• write notations in a report book, for example, to indicate vibrations in equipment or high temperatures which have triggered alarms. (1)
• write cleaning log reports to record specific tasks and times, such as "grain bin hosed out - 11:00 a.m.". (daily) (1)
• write up procedures to keep track of steps in an operation. (occasionally) (2)
• write recipe sheets when changes are being made to ingredients or quantities. (2)
• write reports to supervisors to provide information on production problems and the sequence of events that led up to them. (occasionally) (2)

The numeracy tasks of process control and machine operators in food and beverage processing involve:

• >>> measurement and calculation math at Complexity Levels 1 and 2.
• >> data analysis math at Complexity Levels 1 and 2.

• >> numerical estimation at Complexity Levels 1 to 3.

• measure quantities of liquid and dry ingredients for recipes or batches. (measurement and calculation math) (1)
• may measure the thickness of products, for example, a pizza pop. (measurement and calculation math) (1)
• weigh products to determine packaging requirements. (measurement and calculation math) (1)
• may calculate the volume of syrup, sugar or water from levels shown on a tank. (measurement and calculationmath) (2)
• may read lab test results to determine if a product falls within specifications for that product, for instance 30% butterfat content. (data analysis math) (1)
• may calculate the average usage of ingredients such as salt, sugar and dough over various time periods to verify if the machines are performing consistently. (data analysis math) (2)
• may estimate the distance of hoses from pumping mechanisms when connecting hoses to different pumps. (numerical estimation) (1)
• may estimate how many empty bottles will be required to empty the dispensing machine. (numerical estimation) (2)
• may estimate how much bottle fillingis required for an eight hour shift based on a number of variables, such as whether the machines are running well, how many mixes can be completed per hour and how many staff will be available for the whole shift. (numerical estimation) (3)

a. Mathematical Foundations Used

b. How Calculations Are Performed

• >>> in their head.
• >> using a pen and paper.
• >> using a calculator.

c. Measurement Instruments Used

• >>> time - using a timer, watch, clock or computer console indicator.
• >>> weight or mass - using a scale, balance or gauge.
• >> liquid volume - using a measuring cup, beaker or gauge.
• >>> temperature - using a thermometer or temperature gauge.
• > pressure - using a pressure gauge or control panel gauge.
• > light refraction - using a refractometer to determine the percentage of concentrate in juice.

• >>> the metric measurement system.
• >>> the imperial measurement system.

The typical oral communication tasks of process control and machine operators in food and beverage processing are at Complexity Level 1. Their most complex oral communication tasks are at Complexity Levels 1 and 2.

Process control and machine operators in food and beverage processing:

• may interact with suppliers to discuss orders or to resolve supply difficulties. (1)
• exchange information with co-workers about processes and production levels. (daily) (2)
• communicate with supervisors to clarify instructions or report equipment problems. (frequently) (2)
• may interact with the quality control manager to discuss possible improvements to processes. (monthly) (2)
• may discuss equipment failures with engineers, millwrights or mechanics. (2)

Process control and machine operators in food and beverage processing communicate:

• >>> in person.
• >>> using the telephone.

Noise from machinery, equipment and pumps impedes communication. The wearing of earplugs further hinders conversation.

1. Problem Solving

The typical problem solving tasks of process control and machine operators in food and beverage processing are at Complexity Levels 1 to 3. Their most complex problem solving tasks are at Complexity Levels 1 to 3.

Process control and machine operators in food and beverage processing:

• may find the bread crust is wrinkled. They may change the thickness on a rolling machine or reset the pressure on the machine moulds. (1)
• may find that grain "hangs up" and does not enter the slide to the brewing vats. They place vibrating equipment to open the slides and free the grain. (1)
• may find that there is an incorrect percentage of butterfat in a dairy product, placing it in violation of government regulations on fat content. They may resolve the problem by making another batch of the product and then mixing the two to get the correct level. (2)
• may deal with equipment malfunctions or machine failures. They attempt the repairs themselves, but in some cases have to call maintenance personnel for assistance. They may have to create their own solutions with scrap parts if a supplier cannot supply the needed part immediately. (3)
• may experience a complete computer shutdown, which makes the screens go blank and which automatically halts the process. They call maintenance immediately, performing some steps manually in the interim, if possible. (3)

The typical decision making tasks of process control and machine operators in food and beverage processing are at Complexity Levels 1 to 3. Their most complex decision making tasks are at Complexity Levels 1 to 3.

• decide whether to pull dented cans off the line. (1)
• decide whether to reject a whole batch of a product when a foreign object is found in one small portion of a mix. (2)
• decide when to shut down a machine which is performing poorly, taking into account the consequences on production. (2)
• decide when to change flavours in a production run. (2)
• may decide how to modify a product to make it more appealing to customers' tastes. They make this decision based on past experience with other products and based on consulting sources such as recipe books and magazines. If the modification is not a good one, the result will be lost money for the company. (3)

Process control and machine operators in food and beverage processing plan and organize their job tasks at Complexity Level 2.

Process control and machine operators in food and beverage processing receive instructions from their supervisors on a daily basis. The tasks are repetitive, with some interruptions caused by machine breakdowns or supply shortages. Since processing is a step by step procedure, tasks are performed in the same order every day.

Since processing is generally part of a streamlined, assembly line operation, process control and machine operators co-ordinate their work activities with workers who are part of the same production team. They organize their tasks with strict time lines in mind to respect the schedules of packaging and shipping personnel.

Examples

Process control and machine operators in food and beverage processing:

• remember the steps of processes in sequence.
• remember production targets for a variety of products or batches.
• remember which tanks are running which product and which tanks are being cleaned.
• remember settings and adjustments to gauges and machinery.

5. Finding Information

Process control and machine operators' tasks that involve finding information are at Complexity Levels 1 and 2.

Process control and machine operators in food and beverage processing may:

• refer to ingredient lists to identify ingredients which might be harmful to people with food allergies. (1)
• get information on syrup mixes from a computer database. (1)
• contact product testers at a supplier's laboratory to discuss problems encountered when using a product. (1)
• consult a recipe book for a recipe which has not been used recently. (1)
• may read articles in culinary magazines to find specific information to improve the recipes they are presently using. (2)

Process control and machine operators in food and beverage processing generally work independently. While they may work in their own separate production or control room, they are in close proximity to bottling or packaging lines. They may work with a partner to place raw material into machines. When they are part of an assembly line process, they work as members of a production team.

Process control and machine operators in food and beverage processing:

• >> participate in formal discussions about work processes or product improvement.
• >>> have opportunities to make suggestions on improving work processes.
• >> monitor the work performance of others.
• >>> inform other workers or demonstrate to them how tasks are performed.
• >> orient new employees.
• > make hiring recommendations.
• >> assign routine tasks to other workers.
• > assign new or unusual tasks to other workers.
• > identify training that is required by, or would be useful for, other workers.
• > deal with other workers' grievances or complaints.

The computer use tasks of process control and machine operators in food and beverage processing are at Complexity Level 1.

• > use computer-controlled production machinery which is programmed to check which tanks contain which products and to control time, temperatures and tank cleaning schedules. (1)

Process control and machine operators in food and beverage processing learn on the job, supplemented by training courses in first aid and cardiopulmonary resuscitation (CPR). They may receive instruction from manufacturers on the features of new process machinery. They may attend problem solving or communication courses offered by the company. They may supplement product knowledge by attending trade shows.

• >> as part of regular work activity.
• > from co-workers.
• > through training offered in the workplace.
• > through reading or other forms of self-study:
  > - at work.
  > - on worker's own time.
  > - using materials available through work.
• > through off-site training:
  > - during working hours at no cost to the worker.

In addition to collecting information for this Essential Skills Profile, our interviews with job incumbents also asked about the following topics.

The process control and machine operators in food and beverage processing interviewed mentioned these physical aspects of their jobs.

Body Position

Process control and machine operators in food and beverage processing spend most of their time standing behind a machine. They may walk from workstation to workstation to check valves and tanks. They bend and stretch to adjust products or to clean equipment. They may climb up and down stairs or ladders to reach the top of large vats. Control equipment may be located on several floors. They may be required to enter confined space tanks.

Limb Co-ordination

Process control and machine operators in food and beverage processing use upper limb co-ordination to operate machinery and lift ingredients. Eye hand co-ordination is used when filling tanks or moulds. Operators keep their eyes on the level in the tank, while operating the machine.

Strength

Process control and machine operators in food and beverage processing may lift heavy sacks of flour. They may roll barrels and lift hoses and pumps.

Sensory

Process control and machine operators in food and beverage processing use their sense of smell to recognize the odour of poor quality grain or stale baking supplies.

The process control and machine operators food and beverage processing interviewed felt that process control and machine operators in food and beverage processing should be alert, organized and attentive to detail. They should be team oriented, patient and vigilant.

The growing use of computerized machinery in the food and beverage processing field will increase the need for process control and machine operators in food and beverage processing to be knowledgeable in a variety of specialized computer applications. The advent of the new machinery will increase the need to read operating and repair manuals. Faster machinery will mean that operators may be expected to handle several product lines at once rather than only one. This will increase the need for co-ordinating and organizing skills.

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