Search by process, subject or outcome. Publication states show what can be delivered now and what still requires validation or development.
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WETPROCESSexpertAvailable with site contextualisation
Aseptic Sampling in Dairy Processing
Provides a disciplined method for collecting representative samples without contaminating the sample, product or sampling point. The course covers preparation, hygiene, sample-point control, container handling, labelling, transport and traceability.
What learners will learn
- Prepare personnel, equipment and the sampling point aseptically
- Collect representative samples without introducing contamination
- Protect sample identity, condition and chain of custody
- Recognise invalid samples and take appropriate corrective action
AudienceOperators, quality technicians and personnel collecting microbiological samples
Duration3-5 hours plus observed sampling
PackageLearner guide, knowledge examination and assessor guide
ReferenceUS 19977 support resource
WETPROCESSexpertAvailable with site contextualisation
CIP Solution Titration
Develops practical competence in sampling and titrating cleaning solutions to confirm chemical concentration. The course covers safe chemical handling, sample preparation, indicators, calculations, result interpretation and action when concentration is outside limits.
What learners will learn
- Collect and handle CIP chemical samples safely
- Complete an approved titration method accurately
- Calculate and interpret chemical concentration
- Identify invalid tests and escalate non-conforming results
AudienceCIP operators, quality technicians and sanitation personnel
Duration3-5 hours plus practical demonstration
PackageLearner guide, assessment and assessor guidance
ReferenceUS 19984 support resource
WETPROCESSexpertAvailable with site contextualisation
Centrifugal Separation and Product Standardisation
Develops practical knowledge of separators, clarifiers, cream concentration and product-standardisation systems. Learners connect bowl condition, feed properties, flow, temperature and back pressure with separation efficiency, product composition and fat loss.
What learners will learn
- Explain centrifugal separation and clarification principles
- Identify the function of key separator components and controls
- Assess causes of poor separation, instability and fat loss
- Verify standardisation performance and escalate abnormal results
AudienceSeparator, standardisation, cream and wet-process operators
Duration8-10 hours plus workplace evidence
PackageIllustrated learner guide, knowledge examination and assessor guide
ReferenceDairy separation support resource
WETPROCESSexpertAvailable with site contextualisation
Clean-in-Place Systems and Automated Cleaning
Explains how automated clean-in-place systems achieve effective cleaning through time, temperature, concentration, flow, turbulence and sequence control. Learners examine circuit selection, chemical handling, recovery, verification, faults and hygienic release.
What learners will learn
- Explain the purpose and sequence of CIP stages
- Interpret flow, temperature, concentration and conductivity evidence
- Recognise route, chemical, drainage and contamination failures
- Verify completion and release equipment using site requirements
AudienceCIP, wet-process, powder, packing and sanitation operators
Duration8-12 hours plus workplace evidence
PackageCombined learner guide, knowledge examination, workplace assessment and assessor guide
ReferenceCombined US 28639 and 28632 support resource
WETPROCESSexpertIn validation
Cream Products Processing
Examines cream production from separation and standardisation through storage, heat treatment, cooling and supply to butter or AMF processes. Learners connect fat content, temperature, ageing, agitation and handling with product stability, yield and downstream performance.
What learners will learn
- Explain cream separation, standardisation and treatment steps
- Control fat, temperature, agitation and holding conditions
- Recognise churning, oxidation, contamination and instability risks
- Protect fat yield and downstream butter or AMF performance
AudienceCream, butter, AMF, separation and standardisation operators
Duration8-12 hours plus site activities
PackageComprehensive learner guide; assessment package under validation
ReferenceUS 4830 support resource
WETPROCESSexpertAvailable with site contextualisation
Dairy Processing Fundamentals: Milk Composition and Process Changes
Build a practical understanding of milk composition and how processing changes fat, protein, lactose, minerals, water and physical structure. The course links raw-material variation to separation, heat treatment, concentration, drying, fermentation and final-product performance.
What learners will learn
- Explain the main components of milk and their processing significance
- Describe chemical and physical changes caused by common dairy processes
- Connect raw-material variation with quality, yield and operating risk
- Use composition data to support sound operating decisions
AudienceNew operators, experienced operators moving areas, supervisors and technical staff
Duration6-8 hours plus workplace activities
PackageLearner guide, knowledge examination and assessor guidance
ReferenceUS 4826 support resource
WETPROCESSexpertAvailable with site contextualisation
Dairy Product Filling Operations
Covers preparation, start-up, control and shutdown of dairy filling processes. Learners examine product identity, package integrity, fill accuracy, hygiene, coding, traceability, inspection, reconciliation and the response to packaging or product defects.
What learners will learn
- Prepare filling equipment, packaging and product status
- Control fill quantity, seal integrity, coding and traceability
- Recognise contamination, foreign-matter and package defects
- Reconcile materials and complete safe shutdown and handover
AudienceLiquid, powder, bulk and packaged-product filling operators
Duration6-8 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 20001 support resource
WETPROCESSexpertAvailable with site contextualisation
Dairy Product Holding and Storage
Covers the safe receipt, holding, storage and release of dairy products in silos, tanks and associated transfer systems. Learners examine product identity, temperature control, agitation, contamination prevention, inventory status and abnormal-condition response.
What learners will learn
- Prepare and confirm tanks, routes and product status before transfer
- Control temperature, agitation, holding time and segregation
- Recognise contamination, quality and traceability risks
- Complete safe handovers, records and escalation
AudienceMilk reception, wet-process, silo and transfer operators
Duration4-6 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 20002 support resource
WETPROCESSexpertIn validation
Membrane Separation Processing
Introduces microfiltration, ultrafiltration, nanofiltration and reverse osmosis in dairy processing. The course examines membrane selection, flux, pressure, concentration, diafiltration, fouling, cleaning and the effect of operating conditions on product quality and plant performance.
What learners will learn
- Distinguish the main dairy membrane processes and applications
- Explain pressure, flux, concentration factor and rejection
- Recognise fouling, damage, contamination and performance decline
- Support safe operation, cleaning and performance monitoring
AudienceMembrane-plant operators, supervisors, quality and process-support staff
Duration8-12 hours plus site activities
PackageComprehensive learner guide; assessment package under validation
ReferenceUS 28610 support resource
WETPROCESSexpertIn validation
Milk Reception and Tanker Loading or Unloading
Explains safe, hygienic and traceable loading or unloading of milk and liquid food tankers. The course covers vehicle and product checks, hose and route control, sampling, transfer, reconciliation, cleaning status and abnormal-event response.
What learners will learn
- Verify tanker, product, documentation and route status
- Connect, transfer and disconnect using hygienic controls
- Prevent cross-contamination, overfill, loss and misdirection
- Complete reconciliation, records and incident escalation
AudienceMilk-reception, tanker, dispatch and transfer operators
Duration6-8 hours plus workplace observation
PackageIllustrated learner guide; assessment package under validation
ReferenceBPOPR2009 support resource
WETPROCESSexpertAvailable with site contextualisation
Milk Treatment, Heat Treatment and Pasteurisation Operations
Explains the connected milk-treatment and heat-treatment process, including clarification, standardisation, homogenisation, heating, holding, cooling and product diversion. The course focuses on process purpose, legal and site limits, equipment behaviour and safe response to loss of control.
What learners will learn
- Explain the purpose and sequence of milk-treatment operations
- Interpret pasteurisation time, temperature, flow and diversion controls
- Recognise fouling, leakage, pressure and contamination risks
- Respond to alarms and deviations using approved procedures
AudienceMilk-treatment, pasteurisation, standardisation and wet-process operators
Duration10-14 hours plus workplace evidence
PackageIntegrated learner guide, knowledge examination, workplace assessment and assessor guide
ReferenceIntegrated US 28608, 20005 and 4829 support resource
WETPROCESSexpertAvailable with site contextualisation
Mixing and Blending Operations
Covers preparation, sequencing and control of dairy mixing and blending operations. Learners examine ingredient identity, addition order, dissolution, agitation, temperature, mass balance, allergen and contamination controls, and the consequences of incorrect batching decisions.
What learners will learn
- Prepare ingredients, equipment and authorised formulations
- Apply correct addition sequence, mixing conditions and checks
- Recognise incomplete mixing, foaming, contamination and composition risk
- Reconcile batch quantities and complete controlled records
AudienceBatching, ingredient, formulation and wet-process operators
Duration6-8 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 20009 support resource
WETPROCESSexpertAvailable with site contextualisation
Process Control Interface Operations
Builds operator capability to use process-control interfaces without losing sight of the physical plant. It covers navigation, setpoints, trends, permissives, interlocks, alarms, route status, data quality and disciplined response to abnormal conditions.
What learners will learn
- Interpret process graphics, status indications and trends
- Distinguish alarms, permissives, interlocks and operator actions
- Verify the physical process rather than relying on the screen alone
- Respond, record and escalate control-system abnormalities
AudienceOperators using HMI, SCADA, DCS or automated dairy-process interfaces
Duration6-10 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 21136 support resource
WETPROCESSexpertAvailable with site contextualisation
Pumping and Product Transfer Equipment Operations
Covers pumps, valves, lines and transfer equipment used to move liquids and powders through manufacturing systems. The course links equipment selection and operating conditions with flow, pressure, cavitation, blockage, product damage, contamination and safe isolation.
What learners will learn
- Identify common pump and transfer-equipment types
- Prepare and verify routes before starting a transfer
- Recognise cavitation, blockage, leakage and abnormal loading
- Shut down, isolate and report transfer-system faults safely
AudienceWet-process, powder-transfer, ingredient and utility operators
Duration6-8 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 20012 support resource
WETPROCESSexpertAvailable with site contextualisation
Sampling and Quality Systems
Covers representative sampling, in-process checks, specification use, equipment verification and controlled handling of results. Learners examine how poor sampling or recording can hide process problems and create incorrect product decisions.
What learners will learn
- Select representative sampling points, timing and methods
- Complete routine quality checks using approved equipment
- Record, interpret and communicate results accurately
- Respond to out-of-specification or questionable results
AudienceOperators and quality personnel responsible for routine sampling and checks
Duration6-8 hours plus workplace evidence
PackageLearner guide, knowledge assessment and workplace evidence tools
ReferenceFBPOPR2066 and FBPOPR2070 support resource
POWDERexpertIn development
Dryer Mass Balance and Performance Fundamentals
A planned practical module for understanding water removal, solids flow, yield, losses, energy use and capacity across evaporation and drying. Learners will use site data to separate measurement error from genuine performance loss.
What learners will learn
- Build a basic mass and water balance around the process
- Calculate evaporation and drying loads
- Identify unaccounted solids and likely loss points
- Use performance indicators to prioritise investigation
AudienceDryer operators, supervisors, process engineers and analysts
Duration6-8 hours
PackagePlanned learner module, calculation workbook and case studies
ReferenceINDUSTRYexpert technical module
POWDERexpertFacilitated delivery only
Drying Process Operations
A focused operator module covering preparation, start-up, routine control, fault response and shutdown of a drying process. It is suited to site-specific delivery where the equipment sequence and evidence requirements are built directly around the client plant.
What learners will learn
- Prepare the dryer and supporting systems for production
- Operate within approved process and safety limits
- Identify abnormal conditions and apply safe responses
- Shut down, clean, record and hand over the process
AudienceDryer operators requiring a focused workplace-operating module
Duration8-12 hours plus workplace evidence
PackageWorkbook and assessor guide; facilitated delivery recommended
ReferenceUS 20003 support resource
POWDERexpertAvailable with site contextualisation
Evaporation Operations
Explains falling-film evaporation, vacuum, steam economy, vapour recompression, condensate systems and concentrate control. Learners connect feed properties, heat transfer, flow and fouling with capacity, energy use, product quality and dryer loading.
What learners will learn
- Explain the evaporation process and key equipment functions
- Interpret vacuum, temperature, flow, solids and steam conditions
- Recognise fouling, instability, entrainment and contamination risk
- Support stable operation, cleaning and energy-efficient performance
AudienceEvaporator, wet-process, dryer and process-support personnel
Duration8-12 hours plus workplace evidence
PackageLearner guide or workbook, knowledge assessment and assessor guide
ReferenceUS 20004 support resource
POWDERexpertAvailable with site contextualisation
Fire and Dust-Explosion Prevention
Covers combustible-dust hazards in spray dryers, fluid beds, powder handling and packing systems. The course explains the explosion pentagon, ignition sources, deposits, engineered protection, housekeeping, hot-work controls and safe response to fire or combustion alarms.
What learners will learn
- Explain the conditions required for fire and dust explosion
- Identify credible ignition, fuel, dispersion and confinement hazards
- Recognise the role and limits of engineered protection systems
- Apply safe prevention, alarm response and post-event controls
AudiencePowder operators, supervisors, maintenance, engineering and safety personnel
Duration6-8 hours plus emergency-response review
PackageLearner guide, knowledge examination and contextual assessment
ReferenceUS 16311 support resource
POWDERexpertIn validation
Nutritional Products Processing
Introduces controlled manufacture of nutritional and formulated powder products, including ingredient verification, batching, blending, process hygiene, traceability and packing. Site-specific formulation, allergen and regulatory controls must be added before delivery.
What learners will learn
- Explain the controlled flow of nutritional-product manufacture
- Verify ingredients, formulations, additions and traceability
- Recognise hygiene, allergen, composition and cross-contamination risks
- Support accurate batching, blending, packing and release evidence
AudienceInfant formula, nutritional powder and formulated-product operators
Duration10-14 hours plus site activities
PackageComprehensive learner guide; assessment package under validation
ReferenceUS 31931 support resource
POWDERexpertAvailable with site contextualisation
Powder Filling and Packing Operations
Applies filling-process controls to powder bags, bulk containers and site-specific canning systems. The course covers product and packaging verification, gas flushing where applicable, fill accuracy, sealing, coding, inspection, reconciliation and defect response.
What learners will learn
- Prepare powder, packaging and filling equipment for release
- Control fill weight, gas conditions, seals, seams and coding
- Recognise package-integrity, contamination and foreign-matter defects
- Reconcile output, waste and packaging materials
AudienceBag, bulk, canning and powder-packing operators
Duration6-8 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 20001 support resource
POWDERexpertAvailable with site contextualisation
Powder Handling, Transport and Storage
Covers pneumatic and mechanical powder transfer, hoppers, silos, valves, sifters and associated equipment. Learners examine blockage, segregation, moisture pickup, contamination, dust release, equipment loading and safe recovery from abnormal conditions.
What learners will learn
- Identify common powder-transfer and storage equipment
- Prepare and verify routes before moving powder
- Recognise blockage, bridging, segregation and contamination risks
- Recover, isolate and escalate faults safely
AudiencePowder-transfer, sifter, hopper, silo and packing operators
Duration6-8 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 20012 support resource
POWDERexpertAvailable with site contextualisation
Powder Stickiness in Spray Drying
Examines the material and operating conditions that cause wall deposition, cyclone build-up, fluid-bed fouling and unstable powder handling. Learners use glass transition, moisture, temperature, composition and residence-time concepts to diagnose and reduce stickiness safely.
What learners will learn
- Explain why dairy powders become sticky during drying
- Connect composition and process conditions with deposition risk
- Use trends and evidence to distinguish likely causes
- Develop safe corrective actions without creating new quality or fire risks
AudienceDryer operators, process technologists, supervisors and troubleshooting teams
Duration6-10 hours plus plant review activities
PackageIllustrated learner guide, knowledge examination and assessor guide
ReferenceDAIRYexpert technical module
POWDERexpertAvailable with site contextualisation
Spray Drying Operations
Provides an end-to-end understanding of concentrate preparation, atomisation, drying, powder recovery, fluid-bed treatment, cooling, sifting and packing. The course integrates process control, powder quality, mass balance and fire or dust-explosion prevention.
What learners will learn
- Explain the connected evaporation and spray-drying process
- Relate feed properties and atomisation to particle formation
- Interpret dryer temperatures, airflow, moisture and recovery performance
- Respond safely to deposits, blockages, fire risk and unstable operation
AudienceDryer operators, supervisors, process technologists and engineers
Duration16-24 hours plus workplace evidence
PackageComprehensive illustrated learner guide, knowledge examination, workplace assessment and assessor guide
ReferenceIntegrated US 20003, 4831 and 16311 support resource
BUTTERexpert and AMFexpertAvailable with site contextualisation
AMF Manufacture and Packing
Covers cream concentration, phase inversion, serum separation, oil polishing, dehydration, quality control and packing of anhydrous milk fat. The course links operating conditions with moisture removal, purity, flavour, oxidation, losses and safe product handling.
What learners will learn
- Explain the complete AMF manufacture and packing process
- Interpret separation, polishing, vacuum and moisture controls
- Recognise serum carryover, water, contamination and oxidation risks
- Protect product quality, yield, traceability and packing integrity
AudienceAMF, cream, separator, polishing, dehydration and packing operators
Duration10-14 hours plus workplace evidence
PackageIllustrated learner guide, knowledge examination and assessor guide
ReferenceAMFexpert technical package
BUTTERexpert and AMFexpertIn development
Butter Working, Texture and Temperature Control
A planned specialist module on butter crystallisation, working intensity, tempering, residence time and extrusion behaviour. It will focus on diagnosing texture variation and setting the process for filling, block formation and customer use.
What learners will learn
- Explain how fat crystallisation affects butter texture
- Relate temperature history and working to product structure
- Recognise causes of hard, soft, brittle or oily butter
- Design controlled trials and verify the result
AudienceButter operators, product technologists, supervisors and troubleshooting teams
Duration6-8 hours plus product trials
PackagePlanned learner module, practical trials and troubleshooting guide
ReferenceBUTTERexpert specialist module
BUTTERexpert and AMFexpertIn development
Butter and AMF Packing Operations
A planned module covering hygienic preparation, package selection, fill control, liners, closures, coding, palletisation and cold-chain protection for butter and AMF. Site-specific equipment and packaging specifications will be incorporated.
What learners will learn
- Prepare packing equipment and materials hygienically
- Control fill, closure, coding and package integrity
- Prevent contamination, damage and temperature abuse
- Reconcile packed product, waste and packaging materials
AudienceButter block, bulk, IBC and retail-format packing operators
Duration4-6 hours plus workplace evidence
PackagePlanned learner guide, inspection checklist and workplace assessment
ReferenceBUTTERexpert and AMFexpert packing module
BUTTERexpert and AMFexpertAvailable with site contextualisation
Butter and Margarine Operations
Explains cream preparation, churning or phase inversion, buttermilk removal, washing where applicable, working, moisture and salt control, extrusion and packing. Learners connect fat crystallisation, temperature and mechanical treatment with texture and product performance.
What learners will learn
- Explain the stages of butter and margarine manufacture
- Relate fat structure, temperature and working to texture
- Control composition, moisture, salt and product condition
- Recognise causes of softness, brittleness, leakage and yield loss
AudienceButter, margarine, cream and packing operators
Duration10-14 hours plus workplace evidence
PackageIllustrated learner guide, knowledge examination and assessor marking guide
ReferenceDAIRYexpert butter operations package
BUTTERexpert and AMFexpertIn development
Fat Yield, Recovery and Loss Control
A planned performance module tracing purchased milk fat through reception, separation, cream handling, butter, AMF, by-products, flushes and waste streams. Learners will use mass balance and evidence to distinguish normal process loss from avoidable loss.
What learners will learn
- Map fat flow through the manufacturing process
- Calculate fat yield, recovery and unexplained loss
- Identify measurement, flush, discharge and by-product losses
- Prioritise practical improvement actions and verification
AudienceOperators, supervisors, process engineers and operations managers
Duration6-10 hours plus plant-data exercise
PackagePlanned learner module, loss map and calculation workbook
ReferenceBUTTERexpert performance module
Cheese, infant formula, nutraceutical and packagingFacilitated delivery only
Cheese Making and Manufacturing Operations
Provides a structured introduction to cheese manufacture from milk preparation and starter activity through coagulation, cutting, cooking, draining, salting, pressing and maturation. Facilitated delivery is recommended while the legacy learner material is converted to the current DAIRYexpert standard.
What learners will learn
- Explain the major stages and purpose of cheese manufacture
- Relate milk, culture, rennet, temperature and time to curd development
- Recognise hygiene, composition, yield and defect risks
- Complete controlled workplace evidence across the process
AudienceCheese operators, supervisors and personnel moving into cheese manufacture
DurationApproximately 40 hours plus workplace evidence
PackageLegacy learner resource, 40-hour competency workbook and assessor marking guide
ReferenceDAIRYexpert cheese competency programme
Cheese, infant formula, nutraceutical and packagingIn validation
Frozen Milk Products Manufacture
Covers preparation, freezing, hardening, storage and handling of frozen milk products. Learners examine formulation, overrun where applicable, freezing behaviour, texture, temperature control, hygiene and the causes of common quality defects.
What learners will learn
- Explain the major stages of frozen milk-product manufacture
- Relate formulation and freezing conditions to product structure
- Control hygiene, temperature, hardening and storage
- Recognise texture, ice-crystal and packaging defects
AudienceFrozen dairy-product operators, supervisors and quality staff
Duration8-12 hours plus site activities
PackageComprehensive learner guide; assessment package under validation
ReferenceUS 4307 support resource
Cheese, infant formula, nutraceutical and packagingIn development
Infant Formula and Nutritional Powder Manufacturing
A planned end-to-end programme covering ingredient control, wet and dry blending, thermal processing, concentration, drying, high-hygiene handling, canning and release of infant formula and nutritional powders. Regulatory and site-specific controls will be built into each delivery.
What learners will learn
- Explain the connected infant-formula manufacturing process
- Control ingredients, formulations, allergens and traceability
- Apply high-hygiene and environmental-control requirements
- Recognise composition, microbiological and packaging risks
AudienceInfant formula and nutritional powder operators, supervisors and quality teams
Duration12-20 hours plus workplace evidence
PackagePlanned integrated learner guide, assessment and site hygiene modules
ReferenceINDUSTRYexpert specialist programme
Cheese, infant formula, nutraceutical and packagingIn development
Nutritional Product Formulation Fundamentals
A planned practical introduction to formulation development, ingredient selection, nutrient targets, standardisation, process compatibility and scale-up. It will connect the product brief with what can actually be manufactured, packed and controlled consistently.
What learners will learn
- Translate product requirements into formulation targets
- Assess ingredient function, interactions and processing constraints
- Complete basic composition and standardisation calculations
- Plan trials, scale-up and manufacturing verification
AudienceProduct developers, process technologists, quality staff and manufacturing leaders
Duration8-12 hours plus formulation exercises
PackagePlanned learner module, calculation workbook and scale-up case studies
ReferenceINDUSTRYexpert formulation module
Cheese, infant formula, nutraceutical and packagingAvailable with site contextualisation
Powder Canning and Metal-Container Packing
Applies controlled filling principles to powder canning lines. The programme can cover can preparation, gas flushing, filling, seaming, coding, inspection, line clearance, reconciliation, foreign-matter controls and response to seam or package-integrity defects.
What learners will learn
- Prepare cans, product and line status before release
- Control fill weight, gas flushing, seaming and coding
- Interpret package-integrity and inspection evidence
- Complete line clearance, reconciliation and defect escalation
AudienceCanning operators, area leads, quality personnel and maintenance support
Duration6-10 hours plus workplace evidence
PackageContextualised filling learner guide, workplace assessment and line-specific controls
ReferenceUS 20001 contextualised programme
Cheese, infant formula, nutraceutical and packagingIn development
Soft-Pack Filling and Packaging Controls
A planned module for sachets, pouches, bags and other flexible packaging. It will cover material verification, forming, filling, sealing, coding, inspection, line clearance, reconciliation and the control of seal, leak and print defects.
What learners will learn
- Verify flexible-pack materials and line setup
- Control forming, filling, sealing and coding
- Recognise seal, leak, contamination and print defects
- Complete line clearance and packaging reconciliation
AudienceSachet, pouch, bag and flexible-pack operators and quality personnel
Duration6-8 hours plus workplace evidence
PackagePlanned learner guide, defect library and workplace assessment
ReferenceINDUSTRYexpert packaging module
Food safety and qualityAvailable
Chemical Safety Awareness
Provides practical awareness of chemical labels, safety data sheets, storage, segregation, PPE, dilution, exposure response and incident reporting. It is suitable for induction or refresher delivery and must be aligned with site chemical procedures.
What learners will learn
- Interpret chemical labels and safety data sheets
- Apply storage, handling, PPE and dilution controls
- Recognise incompatible chemicals and exposure routes
- Respond to spills, exposure and emergency situations
AudienceOperators, cleaners, maintenance staff, contractors and supervisors
Duration2-3 hours
PackageLearner guide, assessor guide and competency certificate template
ReferenceINDUSTRYexpert awareness programme
Food safety and qualityIn validation
Foot-and-Mouth Disease Controls
Explains the operational controls used to reduce the risk and spread of foot-and-mouth disease where dairy and livestock supply chains intersect. The course covers biosecurity, movement, cleaning and disinfection, reporting and emergency requirements.
What learners will learn
- Explain how foot-and-mouth disease can spread
- Apply relevant biosecurity and movement controls
- Support cleaning, disinfection and traceability requirements
- Recognise and escalate suspected biosecurity events
AudienceDairy, livestock-interface, milk collection, transport and site-response personnel
Duration4-6 hours
PackageComprehensive learner guide; assessment package under validation
ReferenceUS 16312 support resource
Food safety and qualityAvailable with site contextualisation
Foreign Matter Prevention and Control
Covers prevention, detection and response to physical contamination in food and dairy manufacturing. Learners examine sources, brittle materials, tools and parts, inspection systems, line clearance, housekeeping, incident control and product disposition.
What learners will learn
- Identify likely foreign-matter sources and routes
- Apply prevention, inspection and line-clearance controls
- Respond to breakage, missing parts and detection events
- Protect evidence, traceability and affected product
AudienceOperators, quality, maintenance, warehouse and sanitation personnel
Duration4-6 hours plus site inspection
PackageLearner guide, examination and assessor guidance
ReferenceUS 16302 support resource
Food safety and qualityAvailable with site contextualisation
Good Manufacturing Practice for Food and Dairy
Provides practical GMP training for food and dairy manufacturing, covering personnel practices, hygiene, contamination prevention, documentation, material control, housekeeping, maintenance interaction and reporting. Delivery can be tailored to induction, refresher or role-specific needs.
What learners will learn
- Explain why GMP controls protect product and consumers
- Apply personal, hygiene, material and area controls
- Recognise contamination, documentation and status-control failures
- Report and respond to GMP deviations correctly
AudienceOperators, supervisors, contractors, quality staff and site support functions
Duration4-8 hours depending on role
PackageIllustrated learner guide, assessment and assessor guidance
ReferenceINDUSTRYexpert and DAIRYexpert GMP programme
Food safety and qualityAvailable with site contextualisation
Hygiene and Food Safety Procedures
Covers the personal, environmental and process controls required to protect food during manufacture. The course links hygiene routines, zoning, cleaning, allergen control, illness reporting, waste, pests and corrective action with product-safety outcomes.
What learners will learn
- Apply site hygiene and food-safety procedures
- Recognise contamination routes and high-risk behaviours
- Maintain area, clothing, tool and material controls
- Respond to hygiene and food-safety deviations
AudienceFood and dairy operators, contractors and sanitation personnel
Duration4-6 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 28630 support resource
Food safety and qualityAvailable with site contextualisation
Implementing Food Safety Requirements
Builds practical capability to implement the food-safety requirements that apply to a work area. Learners examine hazards, control measures, monitoring, corrective action, verification, records and escalation within the site food-safety programme.
What learners will learn
- Identify hazards and applicable control measures
- Complete monitoring and records accurately
- Take authorised corrective action when control is lost
- Support verification, investigation and continuous improvement
AudienceOperators and supervisors responsible for implementing food-safety controls
Duration6-8 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 28631 support resource
Food safety and qualityAvailable with site contextualisation
Initial Problem Solving and Root Cause Analysis
Develops a disciplined approach to defining problems, protecting the process, gathering evidence and identifying causes. Learners use practical tools such as 5 Why, cause-and-effect analysis, verification and action tracking without jumping directly to the most convenient explanation.
What learners will learn
- Define the problem, scope and immediate containment
- Collect and organise relevant evidence
- Use structured tools to identify and verify likely causes
- Develop actions and check whether they were effective
AudienceOperators, team leaders, quality staff, engineers and improvement teams
Duration6-10 hours plus workplace investigation
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 28949 support resource
Food safety and qualityAvailable with site contextualisation
Microorganisms: Risks, Testing and Control
Introduces microorganisms relevant to food and dairy manufacture, including pathogens, spoilage organisms and indicators. The course connects growth conditions, hygiene, environmental monitoring, sampling and test results with practical process and product controls.
What learners will learn
- Distinguish major groups of microorganisms and their risks
- Explain factors affecting survival and growth
- Interpret the purpose and limits of common microbiological tests
- Apply controls and respond to adverse results
AudienceOperators, supervisors, quality personnel and hygiene teams
Duration6-8 hours plus site activities
PackageLearner guide, knowledge examination and assessor guide
ReferenceUS 28981 support resource
Food safety and qualityAvailable with site contextualisation
PIC/S GMP for TGA-Regulated Therapeutic Goods
Explains PIC/S GMP requirements for Australian therapeutic-goods manufacturing, including pharmaceutical quality systems, documentation, personnel, premises, equipment, production, quality control, deviations, change control and data integrity.
What learners will learn
- Explain the relationship between the TGA and PIC/S GMP
- Identify the requirements relevant to a site and role
- Apply documentation, status, deviation and change controls
- Recognise situations requiring investigation or quality escalation
AudiencePharmaceutical and nutraceutical manufacturing, quality, warehouse and support personnel
Duration8-12 hours plus role-specific activities
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferencePIC/S PE 009-17 and Australian TGA context
Food safety and qualityIn validation
Product Safety Programme Compliance
Explains how employees and supervisors support compliance with a documented product-safety programme. The course covers programme responsibilities, monitoring, records, deviations, corrective action, verification and the relationship between controlled documents and actual practice.
What learners will learn
- Explain the structure and purpose of a product-safety programme
- Carry out assigned monitoring and documentation duties
- Recognise and escalate non-compliance or loss of control
- Support verification, review and improvement activities
AudienceSupervisors, quality personnel and employees with programme responsibilities
Duration8-12 hours plus site review
PackageComprehensive learner guide; assessment package under validation
ReferenceUS 18405 support resource
Food safety and qualityAvailable with site contextualisation
Quality System Implementation and Monitoring
Covers implementation and monitoring of a workplace quality system, including controlled requirements, responsibilities, records, non-conformance, corrective action, trend review and communication. The course is designed around evidence from the client’s actual system.
What learners will learn
- Explain the structure and responsibilities of a quality system
- Monitor compliance using records and workplace evidence
- Identify, record and escalate non-conformance
- Support corrective action and effectiveness review
AudienceQuality coordinators, supervisors and employees with quality-system responsibilities
Duration8-10 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 28620 support resource
Food safety and qualityIn validation
Sensory Analysis in Food and Dairy Manufacturing
Introduces controlled sensory assessment of food and dairy products. Learners examine sample preparation, panel conditions, attribute language, bias, defect recognition, recording and the limits of sensory evidence in product decisions.
What learners will learn
- Prepare samples and the assessment environment consistently
- Use agreed sensory attributes and scoring methods
- Recognise common bias and invalid assessment conditions
- Record and communicate sensory findings accurately
AudienceOperators, quality personnel, product developers and sensory-panel members
Duration4-6 hours plus practical panel activity
PackageIllustrated learner guide; assessment package under validation
ReferenceFBPOPR2014 support resource
Food safety and qualityAvailable with site contextualisation
Sustainable Environmental Practices
Connects daily manufacturing decisions with water, energy, waste, emissions, chemicals and product-loss outcomes. The course focuses on applying site environmental requirements and identifying practical improvement opportunities without compromising food safety or production control.
What learners will learn
- Identify environmental aspects and impacts in the work area
- Apply site controls for water, energy, waste and chemicals
- Recognise abnormal releases, loss and inefficient operation
- Contribute evidence-based environmental improvements
AudienceOperators, supervisors and employees with environmental responsibilities
Duration4-8 hours plus site activity
PackageLearner guides, assessments and assessor guidance
ReferenceUS 28624 and 28625 support resources
Workplace capability and assessmentIn development
Competency Matrices and Training-Needs Analysis
A planned workshop for defining role capability, mapping required competencies, identifying gaps and setting training priorities. The programme will help organisations replace attendance lists with evidence-based capability management.
What learners will learn
- Define role tasks, risks and required capability
- Build or improve a practical competency matrix
- Identify training, verification and reassessment needs
- Create a prioritised capability-development plan
AudienceTraining managers, supervisors, HR, quality and operations leaders
Duration6-8 hours plus company workshop
PackagePlanned facilitator guide, matrix templates and implementation workbook
ReferenceINDUSTRYexpert capability-system module
Workplace capability and assessmentAvailable with site contextualisation
Interacting with Internal Customers
Applies customer-service principles to internal manufacturing relationships between production, quality, maintenance, warehouse, planning and technical teams. Learners focus on understanding requirements, agreeing priorities, communicating constraints and closing the loop.
What learners will learn
- Identify internal-customer needs and service expectations
- Clarify requests, priorities and constraints
- Communicate progress, delays and completion
- Use feedback to improve internal service and working relationships
AudienceEmployees providing services or information to other departments
Duration4-6 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 28931 support resource
Workplace capability and assessmentAvailable with site contextualisation
Safe Work Practices
Covers practical application of safe-work requirements, hazard identification, permits, isolation awareness, PPE, manual tasks, reporting and stop-work expectations. Site procedures and legal requirements remain the controlling references.
What learners will learn
- Identify hazards and required controls before work
- Apply permits, PPE and safe-work procedures within role authority
- Recognise when work must stop or be escalated
- Report incidents, near misses and changing conditions
AudienceOperators, contractors and employees working in manufacturing environments
Duration4-6 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 28644 support resource
Workplace capability and assessmentIn development
Supervisor Verification and Workplace Evidence
A planned module on collecting reliable workplace evidence without turning supervisors into full-time administrators. It will cover observation, questioning, production records, witness evidence, authenticity, feedback and escalation of doubtful evidence.
What learners will learn
- Identify evidence suitable for workplace verification
- Observe and record performance consistently
- Distinguish verification from formal assessment decisions
- Provide feedback and escalate evidence concerns
AudienceSupervisors, verifiers, assessors and team leaders
Duration4-6 hours plus practical exercises
PackagePlanned learner guide, verifier templates and evidence examples
ReferenceINDUSTRYexpert verification module
Workplace capability and assessmentAvailable with site contextualisation
Working Effectively in a Team
Builds practical teamwork behaviours for manufacturing environments, including communication, role clarity, handover, support, feedback, conflict and shared operating standards. Activities are aligned to the client’s actual team and shift structure.
What learners will learn
- Explain team roles, goals and operating expectations
- Communicate clearly during routine work and handover
- Give and receive constructive feedback
- Support team performance and address issues appropriately
AudienceOperators, team members and emerging leaders
Duration4-6 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 28650 support resource
Workplace capability and assessmentAvailable with site contextualisation
Workplace Assessment Practice
Develops practical capability to plan, conduct, judge and document workplace assessment. The programme addresses evidence rules, fairness, reasonable adjustment, moderation, assessor decisions and the use of authentic workplace evidence.
What learners will learn
- Plan assessment against a standard or competency requirement
- Collect valid, sufficient, authentic and current evidence
- Make and document defensible assessment decisions
- Apply moderation, feedback and reassessment requirements
AudienceWorkplace trainers, assessors, supervisors and competency-system managers
Duration16-24 hours plus assessment portfolio
PackageLearner guide, final examination and assessor guide
ReferenceUS 4098 and 30421-aligned practice resource
Workplace capability and assessmentAvailable with site contextualisation
Workplace Documentation and Document Control
Explains how controlled documents, forms and records support safe and consistent work. Learners examine document status, revision control, access, completion, correction, retention and the consequences of using obsolete or inaccurate information.
What learners will learn
- Distinguish controlled documents, forms and records
- Confirm current revision and authorised use
- Complete and correct records in a traceable manner
- Report document-control failures and improvement needs
AudienceOperators, supervisors, quality staff and document users
Duration4-6 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 28621 support resource
Workplace capability and assessmentAvailable with site contextualisation
Workplace Information and Communication
Develops disciplined use and communication of workplace information, including instructions, records, meetings, handovers and escalation. The course emphasises accuracy, relevance, confidentiality and confirmation that the message was understood.
What learners will learn
- Locate and interpret authorised workplace information
- Communicate operational information clearly and accurately
- Complete handovers and records that support continuity
- Protect confidential information and escalate uncertainty
AudienceOperators, supervisors and employees using production information
Duration4-6 hours plus workplace evidence
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 28653 support resource
Workplace capability and assessmentAvailable with site contextualisation
Workplace Planning
Covers practical planning of work, people, materials, time, equipment and information in a manufacturing environment. Learners consider dependencies, constraints, risk, communication and the response required when the plan changes.
What learners will learn
- Define work requirements, sequence and priorities
- Confirm resources, information and constraints
- Communicate the plan and coordinate dependencies
- Monitor progress and adjust within authority
AudienceOperators, coordinators, team leaders and supervisors
Duration4-6 hours plus planning exercise
PackageLearner guide, knowledge examination, workplace assessment and assessor guide
ReferenceUS 28652 support resource
