FBPGRA4006 — Control mill processes and performance

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What an assessment for FBPGRA4006 must cover

69 assessable components: 9 elements (39 performance criteria), 12 performance evidence and 14 knowledge evidence requirements, plus 4 foundation skills. An audit-defensible tool maps every question and task back to these — that mapping is the coverage matrix Auditori generates alongside the assessment.

Elements & performance criteria

1 Maintain mill flow sheet

1.1Identify all breaking, reduction and dressing stages in mill
1.2Show destinations for all stock separations according to operating requirements
1.3Identify all optional and ancillary equipment required to control flour and by-product production
1.4Identify all bins, silos, chutes, conveyors and exhausts that control processes and performance across the mill

2 Prepare for flour and by-product production

2.1Establish customer requirements for shift or production period
2.2Follow specification required to meet desired production quality and quantity targets
2.3Check availability of required wheat stock
2.4Determine if any changes to grist stock will be required, and plan for changes to settings

3 Determine break system settings

3.1Adjust break rolls for desired percentage release
3.2Conduct visual inspection and test sieving where required to monitor release percentage
3.3Monitor break roll passages to avoid saturation of later stages
3.4Set bran finishers according to workplace procedures and to ensure optimum performance
3.5Set plansifters for desired grading, including adjusting spaces between plansifters for varying grains and moisture levels
3.6Monitor performance of break system to ensure system is free from semolina

4 Set settings for purifiers where fitted

4.1Maintain and monitor sieve covers according to workplace procedures and to ensure optimum performance
4.2Monitor feed rate to purifiers according to workplace procedures and to ensure optimum performance
4.3Monitor horizontal and vertical movement of sieve covers
4.4Set and monitor air pressure for each aspiration section
4.5Select destinations for throughs and lifted bran and other particles
4.6Ensure purifier stock is free from flour

5 Set settings for scratch or sizing system

5.1Set scratch equipment or sizing rolls according to operator instructions
5.2Monitor performance of scratch and sizing rolls

6 Set settings for reduction passages

6.1Set each set of reduction rolls for desired flour and capacity of succeeding reduction passages
6.2Monitor covers on sifters for effective dressing from each reduction roll
6.3Monitor flake disrupters and impact detachers where fitted
6.4Set and monitor reduction settings to achieve required starch damage
6.5Specify collection conveyors and bins for each flour stream

7 Set settings for final production stages

7.1Specify use of flour divides for blends
7.2Monitor redressing equipment according to workplace procedures
7.3Monitor weighing, infestation destroying, and metal removal equipment according to work health and safety and operating procedures
7.4Send finished flour to packing or storage according to workplace requirements

8 Monitor mill equipment

8.1Check flutes and rolls for wear and defects
8.2Monitor temperature of reduction rolls and performance of water cooling if used
8.3Check automatic roll adjustment and protection mechanisms are working correctly
8.4Adjust mill settings when required for effect of breakdowns and urgent maintenance
8.5Complete milling records

9 Monitor mill performance

9.1Ensure all grain and flour tests are carried out to required schedule and procedures
9.2Adjust settings where required for variation in grain, grist and atmospheric conditions
9.3Monitor milling and invisible loss per production period

Performance evidence

interpreting mill flow diagrams and production requirements
identifying customer requirements
determining correct settings for equipment
setting and monitoring break and reduction system equipment
achieving flour specifications through correct use of grist and mill settings
monitoring equipment settings and performance
adjusting mill settings for breakdowns and other contingencies
setting all related processes for: • break • scratch • sizing • reduction and other milling
supervising wheat conditioning
ensuring settings take into account the capability of equipment and the need to avoid imbalances, product build-ups and chokes
ensuring all grain and flour tests are carried out to required schedule and procedures
applying safe work practices and identified work health and safety hazards and controls

Knowledge evidence

alternative and historical milling techniques, including: • stone grinding • ‘low’ or one pass through grinding • use of small manual or electric milling machines • semolina process compared with traditional flour milling process
conventions and techniques in drawing mill flow diagrams
characteristics of different grist and their milling requirements
purpose, design and steps of the break process, including: • overall aim of removing bran from endosperm in large pieces while minimising bran powder and flour • roller design • flute design • roller speed • number of passages • destinations of product from each break roll
purpose, design and principles of the purification process, including: • sieve design • role of sifting, shaking, gravity and aspiration (upward air) • screening decks • exhaust ports and chambers • collection of throughs • overtails • relationship of purification to later reduction stages
scratch equipment and process to remove small pieces of bran and germ from endosperm after sizing or purification
relationship of particle size to reduction roller efficiency
reduction that grinds flour into required fineness while controlling damage to starch granules and minimising abrasion to any bran and germ particles present
features and performance characteristics of milling equipment as specified in manufacturer reference material
relationship between total dressing surface ratio to mill capacity
calculation of break roll percentages
techniques to avoid imbalances, product build-ups and chokes
mill balance requirements and techniques, including: • ensuring that stock does not return to immediate preceding passage or equipment • feed to first break at a constant rate • evenness of feed into rolls • maintenance of conveyor and air settings to achieve constant feed
calculation of mill performance, including: • invisible loss rate • theoretical and actual milling loss rate • procedures to track traceability of product

Foundation skills

Reading: • Interpret mill flow diagrams • Interpret food safety, food labelling and other regulations affecting flour mills
Writing: • Record flour milling equipment status using digital and/or paper-based formats
Oral communication: • Communicate production requirements and technical information to other employees • Use effective communication skills to allocate tasks and provide feedback to team members • Use appropriate vocabulary, including technical language directly relevant to role
Numeracy: • Estimate break roll percentages through visual examination, hand stratification and test sieving

Unit content sourced from training.gov.au — © Commonwealth of Australia, licensed under CC BY 4.0. Auditori is not affiliated with the Department of Employment and Workplace Relations.

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Questions about assessing FBPGRA4006

What does an assessment tool for FBPGRA4006 need to cover?

To satisfy the Principles of Assessment and Rules of Evidence, an assessment for FBPGRA4006 needs to address all 69 unit components: 9 elements with 39 performance criteria, 12 performance evidence requirements, 14 knowledge evidence requirements, and the foundation skills. A coverage matrix mapping each question and task to these components is what an auditor looks for.

How does Auditori generate an assessment tool for FBPGRA4006?

Auditori pulls the current release of FBPGRA4006 from training.gov.au and generates a complete package: candidate assessment, assessor guide with model answers and observation criteria, and a coverage matrix mapping every component. A suitably qualified person then reviews and approves the draft in a built-in workflow — consistent with ASQA's guidance on AI use in VET — before export as branded PDF and editable Word.

Is the first assessment tool really free?

Yes. Every new account includes one free credit — enough to generate the complete assessment tool for FBPGRA4006 — with no card and no subscription required. After that it's pay-as-you-go per unit.

Can I check my existing FBPGRA4006 assessment instead of generating a new one?

Yes — upload your existing assessment or learner guide and Auditori maps it against every element, performance criterion, PE and KE of FBPGRA4006, showing exactly what's covered and what's missing. Mapping costs a quarter of a credit.

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