Model Curriculum. 1. Pickle Making and Processing Technician FOOD PROCESSING FRUITS & VEGETABLES PROCESSING FIC/Q0102, V1.0 4

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1 Model Curriculum 1. Pickle Making and Processing Technician SECTOR: SUB-SECTOR: OCCUPATION: REF ID: NSQF LEVEL: FOOD PROCESSING FRUITS & VEGETABLES PROCESSING FIC/Q0102, V1.0 4

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3 TABLE OF CONTENTS 1. Curriculum Trainer Prerequisites Annexure: Assessment Criteria 10

4 Pickle Making and Processing Technician CURRICULUM / SYLLABUS This program is aimed at training candidates for the job of a Pickle Making and Processing Technician, in the Food Processing Sector/Industry and aims at building the following key competencies amongst the learner Program Name Qualification Pack Name & Reference ID. ID FIC/Q0102, v1.0 Version No. 1.0 Version Update Date 12/01/2016 Pre-requisites to Training Training Outcomes Preferably Class 8 and 2-3 years experience in pickle making unit After completing this programme, participants will be able to: Prepare and process various fruits and vegetables manually or in machine-operated units for pickle-making; Plan, organize, prioritize, inspect, and calculate production requirements and maintain process parameters to achieve the desired quality and quantity; Follow and maintain food safety and hygiene in the work environment; Communicate effectively with peers and seniors.

5 This course encompasses 5 out of 5 National Occupational Standards (NOS) of Pickle Making and Processing Technician Qualification Pack issued by Food Industry Capacity and Skill Initiative. Sr. Module Key Learning Outcomes Equipment Required No. 1 Introduction to the training program 00:30 00:00 Introduce each other and build rapport with fellow participants and the trainer. White board/chart papers, marker Bridge Module 2 Overview of the Pickle making and processing technician Role 01:00 00:00 Understanding the roles and responsibilities of pickle making and processing technician Awareness of the nature and availability of job opportunities Laptop/computer white board, marker, projector, chart papers 3 Introduction to the Food Processing Industry 02:00 00:00 4 Introduction to Fruit & Vegetable Processing 02:00 Define food processing List the various sub sectors of food processing industry State the need for fruit and vegetable processing State the common methods of fruit and vegetable processing. Laptop, white/black board, marker, chart papers, projector,trainer s guide, Student manual Laptop, white/black board, marker, chart papers, projector, trainer s guide, student handbook, pictures/charts of different subsectors in fruit and vegetable processing e.g. pickle,

6 Sr. No. Module Key Learning Outcomes Equipment Required 00:00 FIC/N0109 FIC/N Introduction to the Pickle industry 04:00 00:00 Define pickling and the method of pickling State the different types of picklemaking processes jam and jelly, ketchup, juices, squashes etc. Laptop, white board, marker, chart papers, projector,trainer s guide and student handbook 6 Organizational standards and norms 06:00 00:00 FIC/N0105 FIC/N Prepare and Maintain Work Area and Process Machineries 07:00 16:00 FIC/N0105 State the roles and responsibilities of a pickle-making and processing technician State how to conduct yourself at the workplace State the personal hygiene and sanitation guidelines Identify different equipments used in pickle making process State the materials and equipments used in cleaning and maintenance of the work area and machineries State the cleaning processes used to clean the work Demonstrate the use of different tools and machineries used in pickle making process Identify the appropriate method for cleaning and maintain a work area Ensure the work area is safe and hygienic for food processing Identify and set the machines and tools required for production in working condition Laptop, white board, marker, chart papers, projector, trainer s guide and student handbook, protective gloves, head caps, aprons, safety goggles, safety boots, mouth masks, sanitizer, safety manual Laptop, white board, marker, chart papers, projector, trainer s guide and student handbook, authorized sanitizers, cleansers, all equipments for demonstration

7 Sr. No. Module Key Learning Outcomes Equipment Required Maintain cleanliness of the process machineries required for production using recommended sanitizers 8 Food Microbiology 02:00 05:00 State the types of food microbes State the causes of food spoilage State the process of food spoilage state the criteria to check food spoilage State the need for food preservation State different types of food preservation processes Explain the method of assessing the quality of produce based on physical parameters Laptop, white board, marker, chart papers, projector, trainer s guide and student handbook, samples of fresh and spoiled food 9 Preparation of pickle making and processing 05:00 07:00 FIC/N Execution of pickle making process 08:00 Plan the production schedule as per organizational standards and instructions Organize for raw materials, packaging materials, manpower, equipment and machineries for the scheduled production Identify the raw materials required for production as per production schedule and formation Organize quality raw material as per production process and company standards State the methods for storing raw materials for later use Plan the production sequence to maximize capacity, utilization of resources, manpower and machinery Calculate batch size and prioritize urgent orders based on the production schedule and machine capacity Check the conformance of raw material quality to company standards Check the raw material for quality and grade Prepare the raw material for production State the process for curing raw material and storing cured raw material SOP; ph meter(digital); Thermometer (Digital); Beakers; Measuring Cylinder; Measuring flask; Brinometer; Salinometer, Hydrometer; Weighing Balance (Digital); Brix Meter/ Refractometer; Deep fridge; refrigerator; Gas burner with cylinder; Fruit tray; Stainless steel mug; Cutting knives; mixer/electric mixer; water tank; fruit slicing machine; sealing machine; pickle mixer SOP; ph meter(digital); Thermometer (Digital); Beakers; Measuring Cylinder; Measuring flask; Brinometer; Salinometer, Hydrometer; Weighing Balance (Digital); Brix Meter/ Refractometer;

8 Sr. No. Module Key Learning Outcomes Equipment Required 15:00 FIC/N Packaging and Storage 01:30 02:30 FIC/N0106 FIC/N0107 State the different methods of preparation of pickle Demonstrate the process of preparation of pickle in oil Demonstrate the process of preparation of pickle in brine Demonstrate the process of preparation of pickle in vinegar State the basic categories of packing State the various types of packaging materials used for pickles State the factors for selecting packaging materials State the storage procedures for finished goods Explain the rules of stock rotation for finished goods Deep fridge; refrigerator; Gas burner with cylinder; Fruit tray; Stainless steel mug; Cutting knives; mixer/electric mixer; water tank; fruit slicing machine; sealing machine; pickle mixer, protective gloves; head caps; aprons; safety goggles; safety boots; mouth covers; approved sanitizers; quality and safety manual Different kinds of pickle filling and packaging machines, PET bottles, glass jars, PET pouches 12 Post production cleaning and maintenance 02:00 02:00 FIC/N Complete documentation and record keeping 04:00 Arrange for proper cleaning of production area, equipment, tools and equipment used Organize periodic maintenance of all production machineries 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 Document daily records in the ERP Laptop, white board, marker, chart papers, projector,trainer s guide and student handbook, approved sanitizers, cleansers, cleaning tools, logbooks etc. Laptop, white board, marker, chart papers, projector, trainer s guide and student handbook, logbooks, internal audit register,

9 Sr. No. Module Key Learning Outcomes Equipment Required 02:00 system effectively food safety manual, quality policy etc. FIC/N Food Safety, Hygiene and Sanitation 03:00 05:00 FIC/N Professional and Core Skills 04:00 02:30 16 IT Skills 07:00 12:30 system effectively State the importance of safety, hygiene and sanitation in the baking industry Follow the industry standards to maintain a safe and hygiene workplace Follow HACCP principles to eliminate food safety hazards in the process and products Follow safety practices in the work area Undertake a self-assessment test Identify personal strengths and weaknesses Plan and schedule the work order and manage time effectively to complete the tasks assigned Prevent potential problems from occurring Resolve issues and problems using acquired knowledge and realize the importance of decision making Identify potential problems and make sound and timely decision Improve your reading skills State the importance of listening 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 dayto-day activities Laptop, white board, marker, chart papers, projector,trainer s guide and student handbook, protective gloves, head caps, aprons, safety goggles, safety boots, mouth covers, sanitizer, safety manual,logbooks etc. Laptop, white/black board, marker, chart papers, projector,trainer s guide, Student manual Laptop, white/black board, marker, chart papers, projector, Trainer s guide, Student manual

10 Sr. No. Module Key Learning Outcomes Equipment Required 17 Field Visits 04:00 Observe the factory location, layout and safety aspects of food processing Observe the storage facilities for raw materials and finished products Observe the various machineries All the tools and equipment listed above must be available at the site of field visit used in pickle processing Observe the various machineries 20:00 used in pickle processing Observe the cleaning methods and processes followed to maintain the process machineries and tools Observe the raw materials used and their storage procedures Observe the packaging and storage processes of raw material and finished product Observe the post-production cleaning and maintenance process followed in the industry 18 Revision 01:00 01:00 Revised the knowledge gained so far All the tools and equipment listed above must be available at the time of revision 19 Evaluation 06:00 18:00 20 On-the-job Training 15:00 57:00 Assess the knowledge and skills acquired by the participants Apply the skills and knowledge acquired in the training program in the field All the tools and equipment listed above must be available for evaluation All the tools and equipment listed above must be available on the site at the time of OJT

11 Sr. No. Module Key Learning Outcomes Equipment Required Total Duration 240:00 74:30 165:30 Unique Equipment Required: SOP; ph meter(digital); Thermometer (Digital); Beakers; Measuring Cylinder; Measuring flask; Brinometer; Salinometer; Hydrometer; Weighing Balance (Digital); Brix Meter/ Refractometer; Deep fridge; refrigerator; Gas burner with cylinder; Fruit tray; Stainless steel mug; Cutting knives; mixer/electric mixer; water tank; fruit slicing machine; sealing machine; pickle mixer, protective gloves; head caps; aprons; safety goggles; safety boots; mouth covers; approved sanitizers; quality and safety manual, Different kinds of pickle filling and packaging machines, PET bottles, glass jars, PET pouches Grand Total Course Duration: 240Hours, 0 Minutes (This syllabus/ curriculum has been approved by SSC: Food Industry Capacity and Skill Initiative)

12 Trainer Prerequisites for Job role: Pickle making and Processing Technician mapped to Qualification Pack: FIC/Q0102, v1.0 Sr. No. Area Details 1 Description To deliver accredited training service, mapping to the curriculum detailed above, in accordance with the Qualification Pack FIC/Q0102, Version Personal Attributes An aptitude for conducting training, and pre/ post work to ensure competent, employable candidates at the end of the training, and pre/post work to ensure competent, employable candidates at the end of the training. Strong communication skills, ability to work as part of a team; a passion for quality and for developing others; well-organized and focused, eager to learn and keep oneself updated with the latest in the mentioned 3 Minimum Educational Qualifications 4a Domain Certification 4b Platform Certification fields. B.Sc (home Sc) /B.Tech/BE in Food Technology or Food Engineering with 2 years of hands on experience in Pickle Making Unit or Fruits/Vegetables Processing Certified for Job Role: Pickle making and Processing Technician mapped to QP: FIC/Q0102, v1.0. Minimum accepted score is 80% Recommended that the Trainer is certified for the Job Role: Trainer, mapped to the Qualification Pack: SSC/Q1402. Minimum accepted SCORE IS 80 % as per FICSI guidelines. 5 Experience B.Sc (home Sc) /B.Tech/BE in Food Technology or Food Engineering with 2 years of hands on experience in Pickle Making Unit or Fruits/Vegetables Processing

13 Annexure: Assessment Criteria Assessment Criteria Job Role Qualification Pack FIC/Q0102, v1.0 Sector Skill Council Food Processing Sr. Guidelines for Assessment No. 1 Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC. 2 The assessment for the theory part will be based on knowledge bank of questions created by the SSC. 3 Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training centre(as per assessment criteria below) 4 Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training canter based on this criteria 5 To pass the Qualification Pack, every trainee should score a minimum of 70% (overall) in every QP 6 The marks are allocated PC wise; however, every NOS will carry a weight age in the total marks allocated to the specific QP

14 Assessable Outcome 1. FIC/Q0105: Prepare and maintain work area and process machineries for pickle making 2. FIC/Q0106: Prepare for pickle making Assessment Criteria Total Mark (600) Out Of Marks Allocation Theory Skill s Prac tical PC.1 Prepare clean and maintain the cleanliness of the work area using approved sanitizers and keep it free from dust, waste, flies and pests PC2. Ensure that the work area is safe and hygienic for food PC3. Dispose waste materials as per defined SOPs and industry requirements PC4. For check the working and performance of all machineries and tools used for 100 the pickle making process such as washer, peeler, vegetable cutter/slicer, blender, packaging machines etc. PC5. Clean the machineries and tools used with approved sanitizers following SOP PC6. Place the necessary tools required for process PC7. Attend the minor repairs/ faults of all machines, if required Total PC1. Read and understand the production order from supervisor PC2. Check the availability of raw materials, packaging materials, equipment availability and manpower PC3. Support in planning production sequence PC4. Calculate the batch size based on the production order and machine capacity PC5. Calculate the raw material requirement (considering the process loss) to produce the required quantity of finished PC6. Calculate the raw materials, packaging 100 materials and manpower requirement for completing the order. PC7. Ensure the working and performance of each equipment required for the process PC8. Calculate the process time for effective utilization of machineries PC9. Plan batch size considering full capacity utilization of machineries PC10. Plan to utilize machineries for multiple products without affecting the quality of the finished products, and to optimize production and save energy

15 Assessable Outcome 3. FIC/Q0107: Pickle making Assessment Criteria Total Mark (600) Out Of Marks Allocation Theory Skill s Prac tical PC11. Allot responsibilities and help to assistants and workers PC12. Refer the process chart for products produced PC13. Weigh the raw materials required for the batch PC14. Sharpen/change blades of the cutting/ slicing machine as required for the products produced PC15. Check the conformance of raw material quality to organization standards, through physical analysis and by referring the quality analysis report from the supplier/ internal lab analysis report PC16.Ensure working and performance of required machines and tools PC17. Keep the tools assessable to repair in case of faults/ breakdown Total PC1. Receive vegetables from the supplier/vendor, check weight and check quality through physical parameters such as appearance, colour, texture, maturity PC2. Pump water into the washing tank and control water level, dump vegetable into the washing tank for washing or wash and rinse the vegetables manually PC3. Start the ladder conveyor to lift the vegetables from the washing tank and to transfer to the conveyor PC4. Open valves of the high pressure spraying system for fresh water and adjust pressure to spray water on vegetables for rinsing PC5. Control speed of drying line conveyor, control air temperature and fan speed/ air flow and start conveyor to dry vegetables or start roller conveyor with rolling brushes for wiping and transfer vegetables to sorting line PC6. Start and adjust speed of sorting/ inspecting line conveyor to remove damaged, blemished and rotten vegetables. PC7. Dump the sorted vegetables in the peeling machine, start the peeler

16 Assessable Outcome Assessment Criteria machine and adjust the speed to remove the peel, pump water or open valve/ spraying system to was the peeled vegetables PC8. Prepare lye solution by adding measured quantity of lye chemical and water into lye tank, turn valves to admit steam to heat Iye solution, start conveyor and adjust speed to carry manually/ mechanically into the Lye tank, and pull out the basket after specified time following SOP PC9. Observe vegetable emerging from lye peeling machine/lye tank to ensure removal of peel and open valves to drain excess lye solution PC10. Load the vegetables in the clutter/slicer machine, adjust controls to cut vegetables to required size, start machine, collect sliced vegetables from the discharge chute PC11. Start inspection line conveyor and control speed, transfer cut/ sliced vegetable on the conveyor belt, visually inspect sliced vegetables for conformance to organization standards and remove non-conforming materials from the line PC12. Open valve to admit measured quantity of water into steam jacketed kettle/tank, observe water gauge or designated mark for filled salt as per formulation and add into tank to prepare brine solution PC13.To start and control speed of the agitator of steam jacketed kettle/tank, turn valves to set required pressure and open valve to admit steam to heat the solution following SOP PC14.Observe pressure and temperature gauge and regulate steam to maintain temperature, check brine solution using salinometer equipment to ensure conformance of its specifications to standards PC15. Open valve or start pump to transfer brine solution from mixing tank to storage or holding tanks for later use Total Mark (600) Out Of Marks Allocation Theory Skill s Prac tical

17 Assessable Outcome 1 Assessment Criteria PC16. Start pump to transfer measured quantity of brine solution from storage tank/kettle to the curing drums, add measured quantity of cut/ whole vegetables, close with lid and allow to stand for specified time for curing/natural fermentation following PC17. Mix the vegetables periodically either mechanically/manually for salt equilibrium, sample and check for acidity to ensure completion of fermentation Total Mark (600) Out Of Marks Allocation Theory Skill s Prac tical PC18. Store cured vegetable following SOP until cured PC19. Refer to the work order and formulation for product/ batch PC20. Organize required raw material (cured vegetable), ingredients, spices, packaging material etc. from store and check it conformance to standards through physical parameters PC21. Remove cured vegetable from drums and transfer into the washing tank, pump water into tank to wash vegetables to remove excess salt, open valve to drain water, open valves of the high pressure spraying system for fresh water and adjust pressure PC22.Transfer washed vegetables to the pickle mixing machine, prepare spice mix as per formulation, add measured quantity of spice mixture and oil into the vegetables, adjust controls to set mixing speed and start machine to mix all the ingredients, check the quality of pickle and open valve to transfer pickle into container PC23. Start conveyor and control speed to load cured and washed vegetable into the hopper of the filling machine PC24. Set pickle and oil filling machine and vegetable and brine filling machine for filling quantity and volume, start packaging line conveyor and control speed to ensure containers are positioned under the filling nozzles of pickle/ vegetable and oil/ brine

18 Assessable Outcome 4. FIC/Q0108: Complete documentatio n and record keeping related to pickle making Assessment Criteria Total Mark (600) Out Of Marks Allocation Theory Skill s Prac tical PC25.Load lids and labels in automatic packaging machine, set date code. Start machine, control speed conveyor and observe filling of pickle and oil, vegetable and brine, ensure proper sealing and labelling of containers PC26.Check weight of the filled containers periodically for quantity of vegetable filled and volume of liquid filled to ensure its conformance to standards PC27.Observe filled container leaving machines to detect defects, check the weight of the finished product, sample and transfer to quality lab for analysis PC28.Pack the finished product into cartons and transfer to storage area manually or mechanically and store following organization standards PC29.Report discrepancies to department supervisor for immediate action PC30.Clean equipment and tools using approved cleaning agents PC31. Attend minor repairs of all machines PC32. Ensure periodic maintenance of all machines and equipments Total PC1. Document and maintain records of details of raw materials and packaging materials as per organizational standards PC2. Document and maintain record on observations (if any) related to raw materials and packaging materials PC3. Load the raw material details in ERP for future reference PC4. Verify the documents and track from finished products to raw materials, in 100 case of quality concerns and during quality management system audits PC5. Document and maintain records of production plan with details PC6. Document and maintain records of process details for entire production in process chart or production log for all products produced PC7.Document and maintain records of batch size, production yield, wastage of raw

19 Assessable Outcome 5. FIC/N9001: Food Safety, hygiene and sanitation for processing food products Assessment Criteria Total Mark (600) Out Of Marks Allocation Theory Skill s Prac tical materials, energy utilization and final product produced PC8. Document and maintain record of observations or deviations PC9. Load the production plan and process details in ERP for future reference PC10.Verify documents and track from finished product to ingredients, in case of quality concerns and for quality management system audit PC11. Document and maintain records of finished products PC12. Document and maintain records of the finished product details as per organizational standards PC13. Document and maintain record on observations or deviations (if any) related to finished products PC14. Load the finished product details in ERP for future reference PC15. Verify the documents and track from finished product to ingredients, in case of quality concerns and for quality management system audits Total PC1. Comply with food safety and hygiene procedures followed in the organization PC2. Ensure personal hygiene by use of gloves, masks, hair net, ear plugs, boots etc. PC3. Ensure hygienic production of food by inspecting raw materials, ingredients, finished products etc for compliance to physical, chemical and microbiological procedures PC4. Pack products in appropriate 100 packaging material, label and store them in designated area free from pests, flies etc. PC5. Clean, maintain and monitor food processing equipments periodically, using it only for the specified purpose PC6. Use safety equipment such as fire extinguisher, eye wash unit, first aid kit when required PC7. Follow housekeeping practices by having designated area for machines/tools

20 Assessable Outcome Assessment Criteria Total Mark (600) Out Of Marks Allocation Theory Skill s Prac tical PC8. Follow industry standards like GMP, HACCP and product recall PC9. Attend training on hazard management to understand type of physical, chemical and microbiological hazards PC10.Identify, document and report problems such as rodents and pests to management PC11.Conduct workplace checklist audit before and after work to ensure safety and hygiene PC12.Document and maintain raw material, process, packaging material to maintain the effectiveness of quality system PC13. Determine the quality of food using criteria such as odor, color, taste and best before date and take immediate measures to prevent spoilage PC14. Store raw materials, finished products and allergens separately to prevent cross contamination PC15. Label raw materials and finished products and store them in different storage areas according to safe food practices PC 16. Follow stock rotation based on FEFO/FIFO Total Grand Total Percentage Weightage % 40% Minimum Pass% to qualify (aggregate): 70%

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