apprenticeship curriculum
TRANSCRIPT
APPRENTICESHIP CURRICULUM
For
Seafood Processing, Storage cum Packing Technician
Under
Food Processing
National Apprenticeship Promotion Scheme
1 Program Title : Seafood Processing, Storage cum Packing Technician
2 Program Code, if any NA
3 Any related NSQF approved Fish & Sea Food Processing QP/Course/NOS and code Technician FIC/Q4001, Cold Storage
Technician FIC/Q7004, Packing Machine Worker FIC/Q7002
4 Hours and months for Basic Training 356 Hrs (2 Months) (Block I)
5 Hours and months for On the Job Training 4220 Hrs ( 22 months) (Block II)
6 Certifying body for Basic Training Program Food Industry Capacity & Skill Initiative (FICSI)
7 Certifying Body for On the Job training Industry and FICSI jointly at employer’s location
8 Minimum eligibility criteria 12th Pass/Diploma/ITI with certification in Refrigeration (Educational and/ or technical Qualification) Exemptions, if any B.E (Graduate)/ Diploma/ ITI (NCVT)/ ITI (SCVT), PMKVY/DDUGKY
10 Trainer’s Qualification and Experience B.Sc/B.Tech/BE in or Fisheries Science (BT and OJT) with at least 2 years of hand on
experience in a Fish Processing Unit (marine/in-land)or
• M.Sc/M.Tech/ME in Fisheries Science or Fish Nutrition and Feed Technology or Food Technology or Food Engineering with at least 1 year of hand on experience in a Fish Processing Unit (marine/in-land)
11 Proposed NSQF level 4
12 Indicative list of training tools required to Annexure I deliver this qualification (may be attached)
13 Formal structure of the curriculum
Modules Notional
hours Theory
Notional hours
Practical
Total Duration
Basic Training Program
1. Introduction to Training Program and Overview of Food Processing Industry
2 0 2
2. Prepare and maintain work area and process machineries for processing fish & seafood
5 20 25
3. Prepare for execution of fish & seafood processing
7 20 27
4. Execute fish & seafood processing
4 30 34
5. Handle cold storage facility for storing food
10 85 95
6. Monitor packing machines for various processed food products
5 20 25
7. Complete documentation and record keeping related to processing of fish & seafood
3 6 9
8. Food Safety, Hygiene and Sanitation for processing Food Products
4 11 15
9. Professional and Core Skills 20 34 54
10. IT Orientation 10 60 70
On the Job Training Program
1. Introduction to the training program & Food Processing Industry
8 34 42
2. Organizational Standards and Norms
10 200 210
3. Preparation and Maintenance of Work Area
10 400 410
4. Food Microbiology 12 450 462
5. Preparation for Execution of Fish and Seafood Processing
2 40 42
6. Execution of Fish and Seafood Processing
10 700 710
7. Handle cold storage facility for storing food
8 700 708
8. Monitor packing machines for various processed food products
8 200 208
9 Documentation and Record-Keeping
10 400 410
10. Food Safety, Hygiene, and Sanitation
10 500 510
11. Professional Skills 20 270 290
12. Core/Generic Skills 10 100 110
13. IT Skills 8 100 108
15 Total Pass marks
Total and Pass Marks- Theory
Total and Pass Marks- Practical
Basic Training Program
Total marks - 415 Pass marks- 291
Total marks-685 Pass marks- 480
On the Job Training Program
Total marks-415 Pass marks- 291
Total marks-685 Pass marks- 480
16 Job description- Seafood Processing, Storage cum Packing Technician responsible for grading & processing fish and sea food to achieve quality and quantity of products along with maintaining food safety and hygiene in work environment , handling installation of refrigeration system and components, refrigerant charging and storage of food in the cold storage room by maintaining storage parameters such as temperature and relative humidity in food processing units & monitors the packing machine, loads the packing material, removes the packed food items, checks the quality of the packing visually and segregates the pieces that are not properly packed. The candidates works under supervision and in shifts.
17 Progression from the qualification A candidate after certain amount of experience can work as a supervisor in grading and processing in a fish & seafood industry
18 Employment avenues/opportunities A candidate after successful completion of the course may have the opportunity of working in any fish & seafood industry
19 Assessment strategy 1. Weekly Quiz, Assessed practical, they will be recorded, and evidence maintained in terms of exercise papers and answer papers.
2. Monthly reports for each trainee by the Trainer/ Supervisor. They shall be recorded by each trainer. These will be in terms of description arrived from the marks obtained during weekly quiz and practical/ exercises.
3. Consolidated 3rd party assessment along with Industry where employed as apprentices. Block 1 assessment by 3rd party. It shall have the component of Theory, practical and viva voce, and 4. Consolidated assessment after apprenticeship period jointly (Block-1
and 2) with Industry. 3rd Party shall also be involved. This consolidated assessment shall also have its theory, practical and viva voice components. Their evidence and records shall be maintained and results promulgated to (Basic training and On the Job)
20 Curriculum update version and date V1.0, 05-03-2021
21 Curriculum revision date 04-03-2024
Curriculum
Module Name with duration
Key Learning outcomes
Theory/Basic Training Program- Block I
Introduction to Training Program and Overview of Food Processing Industry Theory Duration (hh:mm) 02:00 Practical Duration (hh:mm) 00:00 Corresponding NOS Code Bridge Module
• State the need and importance of the training program
• Define food processing
• State the roles and responsibilities of fish &seafood processing technician
• Awareness of the nature and availability of job opportunities
Prepare and maintain work area and process machineries for processing fish & seafood Theory Duration (hh:mm)05:00 Practical Duration (hh:mm)20:00 Corresponding NOS Code FIC/N4001
• State the materials and equipment used in the cleaning and maintenance of the work area
• State the common detergents and sanitizers used in cleaning work area and machineries
• State the methods of cleaning and sanitization
• Describe the functions to be carried out before starting grading and processing
• Explain the equipment operation in processing
• State the different types of maintenance procedures
Prepare for execution of fish & seafood processing Theory Duration (hh:mm)07:00
• Identify what are the basic mathematics for various calculations in day-to-day processes
• Describe how to organize the raw materials, packaging materials, manpower, equipment and machineries for the scheduled production
Practical Duration (hh:mm)20:00 Corresponding NOS Code FIC/N4002
• Identify the raw materials required for production as per production schedule and formation
• State the methods for storing raw materials for later use
• Identify the planning of production sequence to maximize capacity, utilization of resources, manpower and
machinery
• State how to calculate batch size and prioritize urgent orders based on the production schedule and machine capacity
Execute fish & Seafood processing Theory Duration (hh:mm) 04:00 Practical Duration (hh:mm) 30:00 Corresponding NOS Code FIC/N4003
• Describe how to obtain and interpret grading specifications
• State how to prepare and maintain work areas used for grading
• Outline how to identify commonly-processed fish species
• State how to grade by size
• Describe how to assess and grade by quality
• Outline the handling methods that maintain the quality and condition
• State why accuracy during grading is important
• State the common quality problems and their likely causes
• Describe how to deal with fish that is not fit for use
• Outline the action to take when the grading specification is not met
• State why it is important to dispose of waste according to company procedures
• Principles of fish Preservation
• Need for fish preservation
• Methods of preservation and treatment of fish before storage
• Describe how to process different types/varieties of fish
• Describe different staff hygiene requirements with regards to fish handling
• Identify the appropriate personnel protective equipment to use in a fish processing plant on-board
• Demonstrate the care and preservation methods of the catch
Handle cold storage facility for storing food Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm)85:00 Corresponding NOS Code FIC/N7011
• Perform a check if all the machineries are clean and in good working conditions
• List the various parts of the refrigeration system correctly
• Demonstrate the installation of refrigeration system
• Perform a pre startup check
• Demonstrate the starting up of the refrigeration system
• Analyze the refrigerant used in the system
• List the control parameters required like the temperature range, atmosphere, storage time at a given temperature
• Demonstrate the setting of machines according to control parameters
• Demonstrate the storing of food products
• Demonstrate the monitoring of machineries during storage
• Demonstrate the recording of parameters in storage chart until storage period
• Inspect, repair/replace refrigeration system and components
• Maintain the entire system and its components
Monitor packing machines for various processed food products Theory Duration (hh:mm) 05:00 Practical Duration (hh:mm) 20:00 Corresponding NOS Code FIC/N7024
• Identify packing specifications from authorized source eg. supervisor, team lead, ERP system, etc
• Identify food product to be packed and its specification in terms of quantity and quality
• Ensure inflow of food product to be packed is suitable as per specifications
• Identify packing material to be obtained, their quantities and any quality criteria that is to be adhered to before packing Packing material: sheets, boxes, cans, or rolls made of plastic, paper, cardboard, cloth or metal; bottles, etc.
• Monitor equipment to identify any discrepancy in operating conditions
• Monitor the packing production line to ensure that there are no discrepancies as per standard
• Prepare for packing by packing machine
• Conduct pre-checks before starting the packing production line
• Monitor the packing production line
• Perform post production activities
Complete documentation and record keeping related to processing of fish & seafood Theory Duration (hh:mm) 03:00 Practical Duration (hh:mm) 6:00 Corresponding NOS Code FIC/N4004
• State the need for documenting and maintaining records of raw materials, processes and finished products
• State the method of documenting and recording the details of raw material to final finished product
• State the process of documenting records of production plan, process parameters, and finished products
Food Safety, Hygiene and Sanitation for processing Food Products Theory Duration (hh:mm) 04:00 Practical Duration (hh:mm) 11:00
• State the importance of safety, hygiene and sanitation in the spice industry
• Identify the industry standards to maintain a safe and hygiene workplace
• Describe HACCP principles to eliminate food safety hazards in the process and products
• Explain safety practices to be followed in the work area specifically related to health hazards associated with working in a spice processing unit
Corresponding NOS Code FIC/N9001
Professional and Core Skills Theory Duration (hh:mm) 20:00 Practical Duration (hh:mm) 34:00 Corresponding NOS Code FIC/N4001
• Undertake a self-assessment test to identify personal strengths and weaknesses
• Plan and schedule the work order and manage time effectively to complete the tasks assigned
• State the importance of decision making
• Identify potential problems and make sound and timely decision
• State the importance of listening
IT Orientation Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 60:00 Corresponding NOS Code Bridge Module
• Identify parts of the computer
• Use the computer keyboard effectively to type
• Use computer applications effectively to record day to-day activities
• Use the word processor effectively
• Use the spreadsheet application effectively
• Use the computer to document day-to-day activities
On the Job Training Program- Block II
Introduction to Training Program and Overview of Food Processing Industry Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 34:00 Corresponding NOS Code Bridge Module
• State the need and importance of the training program
• Define food processing
• State the roles and responsibilities of fish &seafood processing technician
• Awareness of the nature and availability of job
• opportunities
Organizational Standards and Norms Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 200:00
• State the roles and responsibilities of a Sea food processing, Storage cum Packing technician in Industry
• State how to conduct yourself at a workplace
• State the personal hygiene and sanitation guidelines
• State the food safety hygiene standards to follow in a work environment
Corresponding NOS Code FIC/N4002
Preparation and Maintenance of Work Area Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 400:00 Corresponding NOS Code FIC/N4001, FIC/N4002, FIC/N4003, FIC/N9001
• Identify the different equipment used in the fish and seafood processing
• State the materials and equipment used in cleaning and maintenance of the work area and machineries
• State the cleaning processes used to clean the work area
• Describe how to dispose waste as per organizational standards
• Demonstrate the use of different equipment used in fish and seafood processing
Food Microbiology Theory Duration (hh:mm) 12:00 Practical Duration (hh:mm) 450:00 Corresponding NOS Code FIC/N4002
• State the types of food microbes
• State the causes for food spoilage
• State the process for food spoilage
• State the criteria to check food spoilage
• State the need for food preservation
• State the different types of food preservation processes
Preparation for Execution of Fish and Seafood Processing Theory Duration (hh:mm) 2:00 Practical Duration (hh:mm) 40:00 Corresponding NOS Code FIC/N4002, FIC/N4003, FIC/N9001
• List the different varieties of fish and seafood that are processed
• State the quality parameters for raw materials to be processed
• Describe the quality assessment methods based on the physical parameters
• State the various units of measurement used in the food processing industry.
• Calculate the requirement of raw materials for desired quantity of finished product
• List the types and categories of packaging materials used for processed fish and seafood
• State the laws and regulations related to product packaging and labelling
• State the storage requirements for raw materials and finished products
• Determine the quality of food and intake measures to prevent spoilage
• Follow stock rotation based on FIFO/FEFO
• Describe the refrigeration and cold storage facility used for fish and seafood processing
• Describe the storage conditions for all varieties of fish and seafood
• State the storage procedures for raw materials and processed food
• State the documenting procedures for packaging and storing
• Plan the production schedule as per organizational standards and instructions
• Support in planning production sequence
• Organize for raw material, packaging materials, manpower, equipment, and machineries for the scheduled production
Execution of Fish and Seafood Processing Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 700:00 Corresponding NOS Code FIC/N4003
• Describe the process of receiving and handling raw materials
• State the process of grading and sorting varieties of fish and seafood
• State the methods of pre- processing fish and seafood
• Explain the methods of processing fish and seafood
• Demonstrate the process of cleaning the work area and machineries after production
Handle cold storage facility for storing food Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 700:00 Corresponding NOS Code FIC/N7011
• Perform a check if all the machineries are clean and in good working conditions
• List the various parts of the refrigeration system correctly
• Demonstrate the installation of refrigeration system
• Perform a pre startup check
• Demonstrate the starting up of the refrigeration system
• Analyze the refrigerant used in the system
• List the control parameters required like the temperature range, atmosphere, storage time at a given temperature
• Demonstrate the setting of machines according to control parameters
• Demonstrate the storing of food products
• Demonstrate the monitoring of machineries during storage
• Demonstrate the recording of parameters in storage chart until storage period
• Inspect, repair/replace refrigeration system and components
• Maintain the entire system and its components
Monitor packing machines for various processed food products Theory Duration (hh:mm) 8:00 Practical Duration (hh:mm) 300:00
• Identify packing specifications from authorized source eg. supervisor, team lead, ERP system, etc
• Identify food product to be packed and its specification in terms of quantity and quality
• Ensure inflow of food product to be packed is suitable as per specifications
• Identify packing material to be obtained, their quantities and any quality criteria that is to be adhered to before packing Packing material: sheets, boxes, cans, or rolls made of plastic, paper, cardboard, cloth or metal; bottles, etc.
Corresponding NOS Code FIC/N7024
• Identify environmental requirements for packing of the particular food item are in place as per operational guidelines Environmental requirements: e.g. temperature requirements, moisture requirements, non-contamination requirements, cleanliness and hygiene requirements, ventilation requirements, etc.
• Monitor equipment to identify any discrepancy in operating conditions
• Monitor the packing production line to ensure that there are no discrepancies as per standard
• Prepare for packing by packing machine
• Conduct pre-checks before starting the packing production line
• Monitor the packing production line
• Perform post production activities
Documentation and Record-Keeping Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 300:00 Corresponding NOS Code FIC/N4004
• State the need for documenting and maintaining records of raw materials, process, and finished products
• State the method of documenting and recording the details of raw material to final finished product
Food Safety, Hygiene, and Sanitation Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 500:00 Corresponding NOS Code FIC/N9001
• State the importance of safety, hygiene, and sanitation in the fisheries industry
• Follow the industry standards to maintain a safe and hygienic workplace
• Follow HACCP principles to eliminate food safety hazards in the process and products
• Follow safety practices in the work area
Professional Skills Theory Duration (hh:mm) 20:00 Practical Duration (hh:mm) 270:00 Corresponding NOS Code FIC/N4001
• Undertake a self-assessment test
• Identify personal strengths and weaknesses
• Plan and schedule the work order
• Prevent potential problems from occurring
• Resolve issues and problems using acquired knowledge
• Identify control measures to solve issues
• Assess your strengths and weakness
• Work on your strengths and weaknesses
Core/Generic Skills
• Discuss task lists, schedules and activities with the supervisor
Theory Duration (hh:mm) 10:00 Practical Duration (hh:mm) 100:00 Corresponding NOS Code FIC/N4001
• Describe effective communication with the team members
• Question the supervisor in order to understand the nature of the problem and to clarify queries
• Listen attentively and comprehend the information given by the speaker
• Communicate clearly with the supervisor and cross department teams on the issues faced during process
• Understand organizational quality procedures and processes associated with work
• Understand legislations, standards, policies, and procedures followed in the organization relevant to employment, behavior, harassment, discrimination, and performance conditions
• Express and address grievances appropriately and effectively
IT Skills Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 100:00 Corresponding NOS Code Bridge Module
• State the basic functionalities of a computer to perform day-to- day activities
• Use the computer keyboard effectively to type
• Use MS-Word effectively
• Use Excel for effective documentation and record- keeping
List of Assessable outcomes/assessment criteria
Assessable Outcomes
Assessment Criteria Marks Allocation
Total Marks
Out Of Theory Skills
Practical
1. FIC/N4001 (Prepare and maintain work area and process machineries for processing fish and seafood)
PC1. Clean and maintain the cleanliness of the work area using approved sanitizers and keep it free from dust, waste, flies and pests
100 25 10 15
PC2. Ensure that the work area is safe and hygienic for food processing
10 3 7
PC3. Dispose waste materials as per defined sop’s and industry requirements
15 5 10
PC5. Clean the machineries and tools used with approved sanitizers following the company specifications and SOP’s
15 5 10
PC6. Place the necessary tools required for process
5 2 3
PC7. Attend to minor repairs/ faults of all machines, if required
15 5 10
100 35 65
2. FIC/N4002 (Prepare for execution of fish and sea food processing)
PC1. Read and understand the production order from the supervisor
100 10 4 6
PC2. Check the availability of raw materials, packaging materials, equipment and manpower
5 2 3
PC3. Support in planning production sequence by:
• Grouping raw material (various types of fish and seafood) of same type/species
• Selecting raw materials that do not impact the quality of the other
• avoiding CIP after processing each raw material
• Using the same equipment and machinery for various types of fish and seafood
• Planning maximum capacity utilization of machineries
• Considering the process time for each product
• Planning efficient utilization of resources/manpower
• Prioritizing urgent orders
15 5 10
PC4. Calculate the batch size based on the production order and machine capacity
5 2 3
PC5. Calculate the raw material requirement (considering process loss) to obtain required quantity of finished product(s)
5 2 3
PC6. Calculate the raw materials (including ingredients, if any), packaging materials and
5 2 3
manpower requirement for completing the order
PC7. Ensure the working and performance of each equipment required for process
7 2 5
PC8. Calculate the process time for effective utilization of machineries
7 2 5
PC9. Plan batch size considering full capacity utilization of machineries
3 1 2
PC10. Plan to utilize machineries for multiple products without affecting the quality of the finished products, and to optimize production and save energy
3 1 2
PC11. Allot responsibilities/ work to the assistants and helpers
5 2 3
PC12. Refer to the process chart for raw material to be processed
3 1 2
PC13. Weigh the raw materials required for order
3 1 2
PC14. Check the conformance of raw material quality to organization standards, through physical analysis, and by referring to the quality analysis report from the supplier / internal lab analysis report
6 2 4
PC15. Ensure working and performance of required machineries and tools
6 2 4
PC16. Keep the tools accessible to attend repairs/faults in case of breakdown
2 0.5 1.5
PC17. Check the cold storage room for its condition and space availability
5 1.5 3.5
PC18. Set and maintain required temperature of storage area
5 2 3
100 35 65
3. FIC/N4003 (Execution of fish and sea food processing)
PC1. Receive live or chilled raw material (fish and sea food) in refrigerated trucks
100 1 0.5 0.5
PC2. Check the raw material and condition of the transporting vehicle for any possible contamination
1 0.5 0.5
PC3. Check the container to see if the raw material is adequately iced and storage temperature is maintained; check temperature of the raw material
2 0.5 1.5
PC4. Inspect raw material quality through physical parameters like odor, scales, eyes, gills and overall appearance/ physical condition
3 1.5 1.5
PC5. Inspect frozen/chilled seafood for shipping temperature, signs of freezer burn, adequacy of protective covering and integrity of packaging, inspect live shellfish through tap test (tapping live oysters, mussels etc), leg movement (for lobsters, crab)
3 1.5 1.5
PC6. Dump raw material into washing tank for washing , remove washed raw material from water and place in crates/containers
2 0.5 1.5
PC7. Prepare ice flakes and place fresh whole fish and seafood on a bed of ice flakes, cover each layer of fish with layer of ice and store until further processing or weigh the washed raw material and transfer to the preprocessing area
2 0.5 1.5
PC8. Weigh the washed raw material and transfer to the pre-processing area
1 0.5 0.5
PC9. Weigh and transfer raw material to the sorting table
1 0.5 0.5
PC10. Inspect and separate different species of fish and seafood, remove damaged, spoiled, diseased seafood and discard it
3 1 2
PC11. Grade the sorted fish and seafood based on size and quality and place in designated container
3 1 2
PC12. Wash graded fish and seafood manually (or) open valves of the spraying system for water and adjust pressure to wash by spraying water on fish
2 0.5 1.5
PC13. Discard the rejects following the disposal procedure
1 0.5 0.5
PC14. Weigh the graded fish and sea food for pre-processing
1 0.5 0.5
PC15. Remove the shell (in case of shellfish)
5 2 3
PC16. Slit the fish from the throat to the end of the abdomen (gutting)
5 2 3
PC17. Remove the head manually (or) place and position the fish in the deheader machine and press button or lever to cut fish head mechanically (deheading)
5 2 3
PC18. Pull out the gut and egg sac, either before or after deheading (gut pulling)
5 2 3
PC19. Clean out any leftover gut and remove the organs that run down the spine of the fish (spooning)
3 1 2
PC20. Wash with water or by showering with ice water
2 0.5 1.5
PC21. Grade the pre-processed fish and seafood based on size, weight and quality and stack in respective bins
2 0.5 1.5
PC22. Weigh the graded fish and sea food and transfer to the processing area (or) to cold storage room and store maintaining temperature as per organization standards until further processing
2 0.5 1.5
PC23. Receive pre-processed raw material (fish and sea food) for processing
2 0.5 1.5
PC24. Pc23. Thaw fish and seafood (in case of frozen fish and sea food) following SOP
2 0.5 1.5
PC25. Prepare/measure moisture retention agent following sop, weigh raw material and soak in moisture retention agents for retention of moisture, texture, flavor and nutrients
3 1 2
PC26. Control and maintain temperature to pasteurize fish for removal of microbial load
3 1 2
PC27. Transfer pasteurized fish into chilled water to prevent overcooking
1 0.5 0.5
PC28. Remove fish from chilled water, place chilled fish in vibrate belt, adjust controls and start vibrate belt to remove excess water from fish
3 1 2
PC29. Set controls such as temperature, conveyor speed of tunnel freezer and push buttons to start, place fish and seafood on conveyor and allow it to pass through the tunnel freezer to freeze to specified temperature (or) place fish and seafood in trays and load trays in freezer, maintain and control temperature of freezer to freeze fish
5 2 3
PC30. Dip frozen fish in water/ chilled water manually and remove after specified time for glazing (or) start pump to circulate water or control spraying system to spray water, adjust controls to maintain water temperature in glazing machine, adjust speed of the conveyor to allow the frozen fish to dip in water for specified time, and remove glazed fish from conveyor
4 1.5 2.5
PC31. Prepare fillet, cut fillets (dorsal and abdominal muscles) from the backbone and remove the collarbone, remove skin if required, remove pin bones, inspect fillets and remove damages, cut into portions based on weight and parts (like loin, belly flap, tail, etc.), freeze to specified temperature and glaze fillets
4 1.5 2.5
PC32. Pack weighed quantity of the glazed fish and sea food products in primary packaging material and label as well as pack the primary packaged product in cartons
5 1 4
PC33. Sample the product for quality analysis to ensure conformance to standards
3 1 2
PC34. Transfer packed products to cold storage room, and ensure storage temperature is maintained by verifying the temperature gauge at regular intervals
2 0.5 1.5
PC35. Clean the machineries used with approved sanitizers following cip procedure
3 1 2
PC36. Clean the work area, machineries, equipment and tools using recommended cleaning agents and sanitizers
2 0.5 1.5
PC37. Attend minor repairs/faults of all machines (if any)
2 0.5 1.5
PC38. Ensure periodic (daily/weekly/monthly/quarterly/half yearly/annual) maintenance of all machines and equipment following the sop or following suppliers instructions/manuals
1 0.5 0.5
100 35 65
4. FIC/N4004 (Complete documentation and record keeping related to processing of fish and seafood)
PC1. Record details of all raw materials used in the process such as name and variety of raw materials, supplier details, receiving date/ date of manufacture, expiry date, supplier quality document, quality parameters of all raw materials, internal quality analysis report, etc. As per organization standards
100 10 6 4
PC2. Maintain record of observations (if any) related to raw materials, packaging materials
5 3 2
PC3. Load the raw materials details in erp for future reference
5 3 2
PC4. Verify the documents and track from finished product to raw materials, in case of quality concerns and during quality management system audits
5 3 2
PC5. Document process plan with details such as product details, process sequence, equipments and machinery details, efficiency and capacity utilization of equipment
10 6 4
PC6. Document process details such as type/ variety/species of raw material used, process parameters (temperature, time) in process chart or production log for all types of raw materials handled
15 9 6
PC7. Document batch size, raw material used, yield after each stage of process, wastage, energy utilization and final yield
10 6 4
PC8. Maintain record of observations (if any) or deviations related to process and production
5 3 2
PC9. Load the production plan and process details in ERP for future reference
5 3 2
PC10. Verify documents and track from finished product to ingredients, in case of quality concerns and for quality management system audit
5 3 2
PC11. Document and maintain record of types of processed food
3 2 1
PC12. Document the processed food details such as batch number, time of packing, date of manufacture, date of expiry, other label details, primer and secondary packaging materials for all finished products, storage conditions, etc. As per organization standards
7 4 3
PC13. Maintain record of observations or deviations (if any) related to processed food
5 3 2
PC14. Load the finished product details in ERP for future reference
5 3 2
PC15. Verify the documents and track them from processed food to raw materials, in case of quality concerns and for quality management system audits
5 3 2
100 60 40
5. FIC/N9001 (Food safety hygiene and sanitation for processing food products)
PC1. Comply with food safety and hygiene procedures followed in the organization
100 5 2 3
PC2. Ensure personal hygiene by using of gloves, hairnets, masks, ear plugs, goggles, shoes, etc.
6 1 5
PC3. Ensure hygienic production of food by inspecting raw materials, ingredients, finished products, etc. for compliance to physical, chemical and microbiological parameters
5 2 3
PC4. Pack products in appropriate packaging materials, label and store them in designated area, free from pests, flies and infestations
10 4 6
PC5. Clean maintain and monitor food processing equipment periodically, using it only for specified purpose
5 2 3
PC6. Use safety equipment such as fire extinguisher, first aid kit and eyewash station when required
10 4 6
PC7. Follow housekeeping practices by having designated area for materials/tools
5 2 3
PC8. Follow industry standards like GMP and HACCP and product recall process
10 4 6
PC9. Attend training on hazard management to understand types of hazards such as physical, chemical and biological hazards and measures to control and prevent them
5 1 4
PC10. Identify, document and report problems such as rodents and pests to management
5 1 4
PC11. Conduct workplace checklist audits before and after work to ensure safety and hygiene
5 1 4
PC12. Document and maintain raw material, packaging material, process and finished products for the credibility and effectiveness of the food safety control system
4 1 3
PC13. Determine the quality of food using criteria such as aroma, appearance, taste and best before date, and take immediate measures to prevent spoilage
5 2 3
PC14. Store raw materials, finished products, allergens separately to prevent cross-contamination
5 2 3
PC15. Label raw materials and finished products and store them in designated storage areas according to safe food practices
5 2 3
PC16. Follow stock rotation based on FEFO / FIFO
10 4 6
100 35 65
1. FIC/N7011: Handle cold storage facility for storing food
PC1. Interpret technical drawings, inspect the location for setting up refrigeration unit, install condensing unit, mount evaporation coil evaporator
100 3 1 2
PC2. Install piping following industry refrigeration guidelines and applicable codes to ensure proper operation of the refrigeration system, check all wiring connections
3 1 2
PC3. Calculate the number of temperature sensors required for the cold storage facility, identify location to place the sensors and place in relevant locations within the cold storage facility to obtain precise reading
3 1 2
PC4. Charge refrigerant from supply tank to compressor determining charging level through weight and sight glass indication
3 1 2
PC5. Perform pre-start up checks by verifying sufficient refrigerant is charged, electrical connections are tight, wiring and piping are properly routed and secured, compressor mounting bolts are proper, fan motors and mounting brackets are tight, condensing unit base and evaporator coil are properly secured
3 1 2
PC6 Start the refrigeration system and check the compressor discharge and suction pressures to ensure they are in the normal operating range, check the liquid line sight glass for proper refrigerant charge, monitor the compressor oil level and add oil if
3 1 2
necessary to maintain required level.
PC7. Check the voltage and amperage at the compressor terminals, check the piping and electrical connections for vibration
3 1 2
PC8. Check fans on the evaporator coil and condensing unit (for air-cooled condenser) to ensure they are operational and turning in the correct direction, check cooling tower (for water-cooled condenser), ensure there is no refrigerant leakage
3 1 2
PC9. Set the defrost control/timer clock to required time and verify the defrost initiation settings, set temperature control to desired temperature range
3 1 2
PC10.Check the functioning and performance of sensors and temperature measuring device
3 1 2
PC11.Read and understand the work order from the supervisor
3 1 2
PC12.Check all the features of the cold storage facility, operation of the cooling equipment and ensure readiness
3 1 2
PC13.Calibrate temperature and humidity measuring instruments of the storage facility
3 1 2
PC14. Receive food for storage, check the quality of product to be stored in cold storage facility through physical parameters, check the packaging of the product
3 1.5 1.5
PC15. Adjust controls to set storage parameters such as temperature and humidity required for the food of the cold storage room/chamber following the storage parameter chart, check readings to ensure set storage parameters has reached or make required adjustments or set controls in the plc and monitor system (in case of computerized cold storage units)
5 2 3
PC16. Weigh and check the temperature of food, transfer it to the cold storage room and load in the racks either manually or using forklift following sop
3 1 2
PC17. Check the temperature in cold storage room between the cartons on a pallet or between packages inside a carton to ensure proper air circulation
3 1 2
PC18. Observe temperature and humidity and adjusts controls to maintain storage parameters during the entire storage period
3 1 2
PC19. Check temperature of air and stored food periodically for conformance to specifications and standards
3 1 2
PC20. Inspect the storage products periodically for decay, mold growth, sprouting, shriveling, etc.
3 1 2
PC21. Unload stored product immediately after specified storage period and check temperature and weight
3 1 2
PC22. Check the quality of the food from the storage facility through product temperature, and check for shriveling of agricultural produce, freezer burns, mold growth, deterioration, etc.
3 1.5 1.5
PC23.Report any malfunction to the supervisor and implement the suggested corrective action immediately
2 1 1
PC24. Conduct periodic inspection of refrigeration system and components for correct operation, observe operating condition and need for repair or adjustment
3 1 2
PC25. Detect refrigerant leak through system pressure, temperature, recharge volume liquid level etc, to repair recover refrigerant, inspect, rectify and recharge the refrigerant
3 1 2
PC26.Identify malfunction of components, dismantle, repair and replace faulty components
3 1 2
PC27. Reassemble components, test for correct operation, charge system with correct refrigerant, ensure correct operation of the equipment
3 1 2
PC28. Ensure equipment is running efficiently and the required operating conditions are maintained in the cold store chambers for operational requirements
3 1.5 1.5
PC29. Ensure periodic maintenance of refrigeration system and components following sop
1 0.5 0.5
PC30. Check the evaporators for ice accumulation/proper defrosting, wash evaporator coils to remove dust and foreign materials drawn into the fins
2 0.5 1.5
PC31. Check evaporator and condenser fan blades for fractures, clean the fan blades, replace worn blades and tighten the fan set screws, lubricate fan motors, replace fan motor if required
2 0.5 1.5
PC32. Check for the operation of defrost controls, ensure defrost heaters are in the correct position for maximum heat transfer to the evaporator coil, check the voltage at each heater terminal and ensure heater terminals are in good condition
2 0.5 1.5
PC33. Remove foreign materials from the drain pan, check the drain line heater (in case of maintaining freezing temperature)
1 0.5 0.5
PC34. In compressor unit, replace worn condenser motor, check all electrical components and replace damaged wirings and tighten all electrical connections, check and ensure functioning of pressure controls and safety controls, check oil level, ensure working of solenoid valves, check operation of cold room temperature thermostat and clean condenser periodically
4 1 3
PC35. Check condition of refrigerant line insulation and replace if necessary, check refrigerant level in the system, ensure no refrigerant leak
3 1 2
Total
100 35 65
1. FIC/N7010: Prepare and maintain work area and refrigeration requirements
PC.1 Clean and maintain the cleanliness of the work area using approved sanitizers and keep it free from dust, waste, flies and pests
100 25 10 15
PC2. Ensure that the work area is safe and hygienic for food storage
15 5 10
PC3. Dispose waste materials as per defined SOPs and industry requirements
15 5 10
PC4. Check the working and performance of all machineries and tools used for the process such as compressor, condenser, evaporator, fans, sensors, thermostat, humidity meter, etc.
15 5 10
PC5. Clean the equipments and tools used with approved sanitizers following SOP
15 5 10
PC6. Attend minor repairs/faults of equipments, if required
15 5 10
100 35 65
3. FIC/Q7012: Complete
documentation and record
keeping related to the cold
storage facility
PC1. Document and maintain records of incoming food to the storage room/facility, types and varieties of food, weight of food, farmer/vendor details, grown area / geographical location, receiving date, label details such as date of manufacture, date of expiry, quality parameters, date of loading in cold storage facility, intended storage period, outgoing date, type of packaging, loading pattern, storage location within the cold storage unit, etc. following SOP
100 10 6 4
PC2. Document and maintain records of all outgoing food from the cold storage facility such as type and varieties of food, weight of food, actual storage period, losses from incoming to outgoing period, quality of food during unloading from cold storage unit, packaging condition, etc. following SOP
5 3 2
PC3 Maintain record of observations (if any) related to storage
5 3 2
PC4. Load the details in ERP system for future reference
5 2 3
PC5. Verify the documents and track details in cases of concerns
10 6 4
PC6. Document and maintain records of parameters such as temperature, relative humidity of the food before loading in the cold storage facility, during storage period and during unloading from the storage facility for each food stored following SOP
15 9 6
PC7. Document and maintain records of parameters such as temperature, relative humidity of the cold storage room/facility before loading, during storage and during unloading following SOP
10 6 4
PC8. Maintain record of observations or deviations (if any) related to storage parameters
5 3 2
PC9. Load the details in ERPsystem for future reference
5 3 2
PC10. Maintain record on observations or deviations (if any)
5 3 2
PC11. Document and maintain records of the technical drawings of cold storage room/chamber, refrigeration system and components, electrical lines, etc.
5 3 2
PC12. Document and maintain records of refrigeration system such as type of refrigeration unit, type of refrigerant, quantity of refrigerant used, cooling system followed, component details such as type of compressor, condenser, evaporator, fans etc following sop
6 4 2
PC13. Document and maintain records of operating conditions of cold storage room by recording temperature of food and air in the cold storage room/chamber, compressor pressure, ice formation etc
5 3 2
PC14. Document and maintain records of preventive maintenance, routine checks, inspections, faults identified, repairs, replacements, refrigerant leak, recharge, quantity and kind (new, reused or recycled etc of refrigeration system and components following sop
3 2 1
PC15.Maintain record of observations or deviations (if any)
2 1.5 0.5
PC16.Load the details in ERP system followed by the organisation for future reference
2 1.5 0.5
PC17. Verify the documents and track details in cases of concerns
2 1 1
100 60 40
4. FIC/N9002 Use basic health and
safety practices at a
food
PC1.use protective clothing/equipment for specific tasks and work conditions
100 5 2 3
PC2.state the name and location of people responsible for health and safety in the workplace
3 1 2
processing workplace
PC3.identify job-site hazardous work and state possible causes of risk or accident in the workplace
3 1 2
PC4.carry out safe working practices while dealing with hazards to ensure the safety of self and others
5 2 3
PC5.state methods of accident prevention in the work environment of the job role
3 0 3
PC6.state location of general health and safety equipment in the workplace
3 0 3
PC7.work safely in and around trenches, elevated places and confined areas
5 2 3
PC8.handle all food and related materials safely using correct procedures
5 2 3
PC9.apply good housekeeping practices at all times
5 2 3
PC10.identify common hazard signs displayed in various areas
5 2 3
PC11.adhere to relevant food safety policies such as propriety product policy, gloves policy, pest control policy, restrictions on harmful chemicals inside work area during production
5 2 3
PC12.use the various appropriate fire extinguishers on different types of fires correctly
4 1 3
PC13.demonstrate rescue techniques applied during fire hazard
4 1 3
PC14.demonstrate good housekeeping in order to prevent fire hazards
4 1 3
PC15.demonstrate the correct use of a fire extinguisher
3 1 2
PC16.demonstrate how to free a person from electrocution
4 1 3
PC17.administer appropriate first aid to victims where required e.g. in case of bleeding, burns, choking, electric shock, poisoning, etc.
4 1 3
PC18.demonstrate basic techniques of bandaging
4 1 3
PC19.respond promptly and appropriately to an accident situation or medical emergency in real or simulated environments
4 1 3
PC20.perform and organize loss minimization or rescue activity during an accident in real or simulated environments
4 1 3
PC21.administer first aid to victims in case of a heart attack or cardiac arrest due to electric shock, before the arrival of emergency services in real or simulated cases
3 1 2
PC22.demonstrate the artificial respiration and the CPR Process
3 1 2
PC23.participate in emergency procedures
4 1 3
PC24.complete a written accident/incident report or dictate a report to another person, and send report to person responsible
4 1 3
PC25.demonstrate correct method to move injured people and others during an emergency
4 1 3
100 30 70
5. FIC/N9003: Food Safety, hygiene and sanitation for cold storage
PC1. Comply with food safety and hygiene procedures followed in the organization
100 5 2 3
PC2. Ensure personal hygiene by using of gloves, hairnets, masks, ear plugs, goggles, shoes, etc.
6 1 5
PC3. Ensure hygienic production of food by inspecting raw materials, ingredients, finished products etc for compliance to physical, chemical and microbiological procedures
5 2 3
PC4. Pack products in appropriate packaging material, label and store them in designated area free from pests, flies etc.
10 4 6
PC5. Clean, maintain and monitor food processing equipments periodically, using it only for the specified purpose
5 2 3
PC6. Use safety equipment such as fire extinguisher, eye wash unit, first aid kit when required
10 4 6
PC7. Follow housekeeping practices by having designated area for machines/tools
5 2 3
PC8. Follow industry standards like GMP, HACCP and product recall
10 4 6
PC9. Attend training on hazard management to understand type of physical, chemical and microbiological hazards
5 1 4
PC10.Identify, document and report problems such as rodents and pests to management
5 1 4
PC11.Conduct workplace checklist audit before and after work to ensure safety and hygiene
5 1 4
PC12.Document and maintain raw material, process, packaging material to maintain the effectiveness of quality system
4 1 3
PC13. Determine the quality of food using criteria such as odor, color, taste and best before date and take immediate measures to prevent spoilage
5 2 3
PC14. Store raw materials, finished products and allergens separately to prevent cross contamination
5 2 3
PC15. Label raw materials and finished products and store them in different storage areas according to safe food practices
5 2 3
PC16. Follow stock rotation based on FEFO/FIFO
10 4 6
100 35 65
6. CSC/N1336: Use basic health and
safety practices at a
food processing workplace
PC1. accurately receive information and instructions from the supervisor and fellow workers, getting clarification where required
100 10 3 7
PC2. accurately pass on information to authorized persons who require it and within agreed timescale and confirm its receipt
10 3 7
PC3. give information to others clearly, at a pace and in a manner that helps them to understand
10 3 7
PC4. display helpful behavior by assisting others in performing tasks in a positive manner, where required and possible
10 3 7
PC5. consult with and assist others to maximize effectiveness and efficiency in carrying out tasks
10 3 7
PC6. display appropriate communication etiquette while working
10 3 7
PC7. display active listening skills while interacting with others at work
10 3 7
PC8. use appropriate tone, pitch and language to convey politeness, assertiveness, care and professionalism
10 3 7
PC9. demonstrate responsible and disciplined behaviors at the workplace
10 3 7
PC10. escalate grievances and problems to appropriate authority as per procedure to resolve them and avoid conflict
10 3 7
100 30 70
7. FIC/N7024 (Monitor packing
machines for various
processed food products)
PC1. obtain packing specificationsfrom authorized source eg. supervisor, team lead, ERP system, etc.
100 2 0 2
PC2. identify food product to be packed and its specification in terms of quantity and quality
3 1 2
PC3. ensure inflow of food product to be packed is suitable as perspecifications
3 1 2
PC4. identify packing material to be obtained, their quantities and any quality criteria that is to be adhered to before packing
3 1 2
PC5. obtain packing material as per the job specification received
2 0 2
PC6. check if the packing material is as per required quantity and quality standard
3 1 2
PC7. ensure the packing machine isin operating condition
2 0 2
PC8. use the appropriate personal protective equipment (PPE)
4 1 3
PC9. ensure environmental requirementsfor packing of the particular food item are in place as per operational guidelines
3 1 2
PC10. load, position, or feed the food product in the packing machine as per manufactures guidelines and packing specifications
4 1 3
PC11. load, position or feed the packing materials in the packing machine as per manufactures guidelines and packing specifications
4 1 3
PC12. enter the operating parameters as per the production requirements given in the packing specification
3 1 2
PC13. produce sample packing and check if the packing is as per specifications
4 1 3
PC14. adjust operating parameters to correct the faults identified in the samples till the packing is as per acceptable standards
4 1 3
PC15. monitor equipment to identify any discrepancy in operating conditions
3 1 2
PC16. report the discrepancies identified to the supervisor or maintenance staff as per operational guidelines
2 0 2
PC17. start production as per workplace procedures, taking all safety and hygiene related precautions
4 1 3
PC18. monitor the packing production line to ensure that there are no discrepancies as per standard
4 2 2
PC19. identify non-standard output product by visual inspection
3 1 2
PC20. perform integrity testing on the packed items as per operational guidelines
4 1 3
PC21. segregate and label the non-standard materials and packages which do not meet the specification
4 2 2
PC22. hand over standard and non-standard packed products as per operational guidelines, with minimum damage
3 1 2
PC23. maintain the supply of packing materials throughout the run
2 0 2
PC24. ensure that the required output rates are maintained
2 0 2
PC25. identify discrepancies, non-standard out-put, problems and immediately report to the supervisor to ensure immediate resolution of the problem
4 1 3
PC26. shut down the packing production line in case of emergencies
2 0 2
PC27. follow the correct procedures for the removal of waste
3 1 2
PC28. clean the machine after use as per operational guidelines and manufacture's guidelines
3 1 2
PC29. identify and report equipment faults as per operational guidelines
2 0 2
PC30. store re-usable materials and equipment in designated area in a condition ready for re use.
2 0 2
PC31. perform relevant documentation like production details, quality details, maintenance details, etc.
2 0 2
PC32. comply with relevant legislation for food processing and packaging norms
3 0 3
PC33. adhere to organizational standards, policies and procedures with respect to operation of the food item packing machine
4 2 2
100 25 75
Annexure A:
List of Tools and Equipment (For a batch of 30 students)
Sr No Tool/ Equipment Name Quantity
1 Scaling machine 1
2 Shelling machine 1
3 Grounding machine 1
4 Opening machine 1
5 Thermo formers 1
6 Moulders 1
7 Heat sealers 1
8 Can making equipment 5
9 Can closers/ sealers 5
10 Seam testers 5
11 Fillers of all type 10
12 Cutting / slitting / trimming equipment 10
13 Typing / sieving/ stapling equipment 10
14 Closing / sealing equipment 10
15 Form / fill/ seal equipment 10
16 Cappers/ crumpers/ hoofers 5
17 Wrappers 5
18 Cartoners 5
19 Multipackers 10
20 Bundlers 10
21 Shrink wrappers and tunnels 10
22 Labellers 15
23 Coding equipments 1
24 Check weighers 1
25 Metal detection equipment 1
26 Level checking equipment 1
27 Code/ lable inspecting equipment 1
28 Printing equipment 1
29 Palletisers 1
30 Bottle spotters 1
31 Aligners 1
32 Container cleaning/ washing/ drying systems
10
33 Accumulator/ collectors 1
34 Unloaders 1
35 stackers 1
36 Feeding/ orienting equipment 1
37 coats and aprons 30
38 Ear plugs or muffs 30
39 eye and facial protection 30
40 head-wear 30
41 lifting assistance 1
42 mesh aprons 30
43 protective boot covers 30
44 protective hand and arm covering 30
45 protective head and hair covering 30
46 work uniforms 30
47 safety and waterproof footwear 30
48 containers 5
49 utensils 30
50 hand tools 10
51 lifting aids 10
52 stacking equipment 10
53 processing unit 1
54 conveyor and processing belts 1
55 Compressor 1
56 Condenser 1
57 Evaporator 1
58 Fans 1
59 Sensors 1
60 Thermostat 1
61 Humidity Meter 1
62 Safety Goggles 30
63 Mouth Masks 30
64 Sanitizer 5
65 Food Safety Manual 15
66 Log Books 30
67 Computer/Laptop 5