Run an allergen changeover on snack line 2

You are a Production Operator on snack line 2 at Dandenong South.

Simulated workplaceIntermediate missionCAQA Orchard Lane Foods

What is going on

Snack line 2 finishes a run of apricot and almond fruit bars, which contain tree nuts, at the end of day shift. The first product on afternoon shift is apple and strawberry fruit bars, which are allergen free. The Allergen Management Policy requires a validated changeover between the two products and the line cannot start until the visual inspection and the allergen swabs have passed. Line leader Liam Fitzgerald is supervising and Priya Nair from quality will take the swabs. Earlier this week an obsolete sleeve with a superseded allergen statement was found in the packaging bay, so the label check for the new product is being watched closely.

Liam Fitzgerald, Line Leader, Snack Line 2
Subject: Changeover to apple and strawberry after the almond run

We finish the apricot and almond bars at the end of day shift tomorrow and apple and strawberry runs first thing on afternoon shift. That is a full allergen changeover from tree nuts to allergen free. I want you to run it under my supervision: line clearance, dry and wet clean, clean in place on the allergen cycle, visual check, then swabs with Priya before the line starts. Complete the changeover record and the label check for the new product and enter the changeover result in the monitoring log. Do not start the line until the swab result is recorded as a pass.

Your brief

Complete the full allergen changeover from line clearance to verified clean and set up in line with the procedure, complete the changeover record and the label check, and enter the result in the critical control point monitoring log so the next batch can start.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

Read the Allergen Management Policy and the Allergen Changeover and Line Clearance Procedure and list the steps in order with the record required at each step.
Check the product specifications for both products in the batch record notes and confirm with Liam Fitzgerald that a full changeover is required.
Complete the line clearance, removing and labelling rework and removing all apricot and almond packaging and labels, and record it on the changeover record.
Carry out the dry clean, wet clean and sanitise using the colour coded allergen cleaning equipment and start the clean in place allergen cycle, recording each step and time.
Present the line for visual inspection, support Priya Nair while she takes swabs from the locations on the line diagram, and record the results.
Set up the line for apple and strawberry, complete the label check against the approved artwork and record a non-conformance if any packaging does not match.
Enter the changeover result in the Critical Control Point Monitoring Log and open the new batch in the Production Batch Records system with the changeover reference.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Completed changeover record
Monitoring log entry for the allergen changeover
Label check record for the new product
New batch record opened with references

Printing this is a record of what you explored. It is not a certificate or a qualification.