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SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD THAT HAS PASSED THE END DATE: 

Operate a forming, filling and sealing process on a food automated packaging line 
SAQA US ID UNIT STANDARD TITLE
242785  Operate a forming, filling and sealing process on a food automated packaging line 
ORIGINATOR
SGB Food 
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY
-  
FIELD SUBFIELD
Field 06 - Manufacturing, Engineering and Technology Manufacturing and Assembly 
ABET BAND UNIT STANDARD TYPE PRE-2009 NQF LEVEL NQF LEVEL CREDITS
Undefined  Regular  Level 4  NQF Level 04  18 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Passed the End Date -
Status was "Reregistered" 		 2018-07-01  2023-06-30  SAQA 06120/18 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2024-06-30   2027-06-30  

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.  

This unit standard replaces: 
US ID Unit Standard Title Pre-2009 NQF Level NQF Level Credits Replacement Status
9056  Operate and control aseptic forming, filling, and sealing of containers for food products  Level 3  NQF Level 03  18   
9130  Operate and control the forming, filling and hermetic sealing of plastic sachets or bags for food products  Level 2  NQF Level 02  10   

PURPOSE OF THE UNIT STANDARD 
This unit standard is intended for a person working on a food or beverage automated packaging line who is responsible performing forming, filling and sealing operation.

A person credited with this unit standard can safely:
  • Demonstrate understanding of forming, filling and sealing equipment.
  • Prepare and start forming, filling and sealing equipment.
  • Operate forming, filling and sealing equipment.
  • Shutdown forming, filling and sealing equipment.
  • Prepare for and perform changeovers on forming, filling and sealing equipment. 
    		•

    LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    It is assumed that learners are already competent in Communication and Mathematical Literacy at NQF Level 2. 

    UNIT STANDARD RANGE 
    N/A 

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Demonstrate understanding of forming, filling and sealing equipment. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The type of forming, filling and sealing equipment used is described according to supplier specifications and standard operating procedures. 

    ASSESSMENT CRITERION 2 
    The characteristics of raw material are described according to their composition and the rationale' for their utilisation. 
    ASSESSMENT CRITERION RANGE 
    Raw materials (Wet):
  • Glass Bottles
  • Plastic Bottles
  • Cans
  • Cartons
  • Sachets
  • Bags
  • Pouches
  • Trays
  • Barrels
  • Buckets
  • Cartridges
  • Tubs
  • In process product

    Raw materials (Dry):
  • Glass Containers
  • Pouches
  • Cans
  • Cartons
  • In process product
     
    		•

    ASSESSMENT CRITERION 3 
    The services required for the forming, filling and sealing equipment to produce are identified and described according to their nature and characteristics. 
    ASSESSMENT CRITERION RANGE 
    Services:
  • Electricity
  • Compressed Air
  • Water
  • Gas
     
    		•

    ASSESSMENT CRITERION 4 
    The role of the forming, filling and sealing process in the packaging process is described according to food manufacturing principles and practice. 

    ASSESSMENT CRITERION 5 
    Statistical techniques to measure the performance of the forming, filling and sealing equipment and the quality of output are described and utilised. 

    ASSESSMENT CRITERION 6 
    The procedures for start up, fill, shutdown, and changeovers are described according to standard operating procedures. 

    ASSESSMENT CRITERION 7 
    Deviations are that could occur on the forming, filling and sealing equipment and the corrective actions that would be taken are described as per standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
    Deviations:
  • Quality
  • Equipment
  • Operating and process deviations
     
    		•

    ASSESSMENT CRITERION 8 
    Demonstrate an understanding of the relevant Health Safety and Environmental standards as per legislation. 
    ASSESSMENT CRITERION RANGE 
    Includes:
  • Occupational Health and Safety Act
  • National Environmental Management Act
  • Company Standards such as NOSA, ISO 9002 and ISO 14000
  • Foodstuffs, Cosmetics and Disinfectants Act No 54 of 1972
  • SABS Food Hygiene Management Code 49 : 1989
     
    		•

    SPECIFIC OUTCOME 2 
    Prepare and start forming, filling and sealing equipment. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Production plan is obtained and interpreted as per standard operating procedure before forming, filling and sealing equipment is prepared and started. 
    ASSESSMENT CRITERION RANGE 
    Production plan includes the following information, volumes, brands, shift information, packaging requirements, production specifications.
     

    ASSESSMENT CRITERION 2 
    Raw materials and services for production plan are sourced and available as per standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
    Raw materials can be specified under two types of finished product "wet" or liquid packaging and "dry" products.

    Raw materials (Wet):
  • Glass Bottles
  • Plastic Bottles
  • Cans
  • Cartons
  • Sachets
  • Bags
  • Pouches
  • Trays
  • Barrels
  • Buckets
  • Cartridges
  • Tubs
  • In process product

    Raw materials (Dry):
  • Glass Containers
  • Pouches
  • Cans
  • Cartons
  • In process product

    Services:
  • Electricity
  • Compressed Air
  • Water
  • Gas
     
    		•

    ASSESSMENT CRITERION 3 
    Forming, filling and sealing equipment is inspected for ability to produce as per standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
    Forming, filling and sealing equipment (Wet)
  • Bottle fillers
  • Sachet Fillers
  • Barrel Fllers
  • Can Fillers
  • Pouch Fillers
  • Tray Fillers
  • Bag Fillers

    Forming, filling and sealing equipment (Dry):
  • Bottle Fillers
  • Can Fillers
  • Tray Fillers
  • Bag Fillers
     
    		•

    ASSESSMENT CRITERION 4 
    Forming, filling and sealing equipment is inspected for cleaning and sanitation as per standard operating procedure. 

    ASSESSMENT CRITERION 5 
    Forming, filling and sealing equipment is started as per standard operating procedure. 

    ASSESSMENT CRITERION 6 
    Health Safety and Environmental standards are adhered to as per legislation. 
    ASSESSMENT CRITERION RANGE 
    Includes:
  • Occupational Health and Safety Act
  • National Environmental Management Act
  • Company Standards such as NOSA, ISO 9002 and ISO 14000
     
    		•

    SPECIFIC OUTCOME 3 
    Operate forming, filling and sealing equipment. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Forming, filling and sealing equipment is operated as per standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
    Forming, filling and sealing equipment (Wet):
  • Bottle Fillers
  • Sachet Fillers
  • Barrel Fillers
  • Can Fillers
  • Pouch Fillers
  • Tray Fillers
  • Bag Fillers

    Forming, filling and sealing equipment (Dry):
  • Bottle Fillers
  • Can Fillers
  • Tray Fillers
  • Bag Fillers
     
    		•

    ASSESSMENT CRITERION 2 
    Quality is checked and recorded as per standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
    Quality:
  • Packaging raw material
  • Incoming process quality
  • Incoming Product
  • Control parameters
  • Services
  • Outgoing process quality
  • Products
  • Returnable packaging raw material
  • Waste
     
    		•

    ASSESSMENT CRITERION 3 
    Production inputs and outputs are measured and recorded as per standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
    Inputs:
  • Packaging material
  • Incoming product
  • Control parameters
  • Services
  • Outputs
  • Products
  • Returnable packaging materials
  • Waste
     
    		•

    ASSESSMENT CRITERION 4 
    Deviations are identified, recorded and corrective action is taken as per standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
    Deviations:
  • Quality
  • Equipment
  • Operating and process deviations
     
    		•

    ASSESSMENT CRITERION 5 
    Health Safety and Environmental standards are adhered to as per legislation. 
    ASSESSMENT CRITERION RANGE 
    Includes:
  • Occupational Health and Safety Act
  • National Environmental Management Act
  • Company Standards such as NOSA, ISO 9002 and ISO 14000
     
    		•

    SPECIFIC OUTCOME 4 
    Shutdown forming, filling and sealing equipment. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Forming, filling and sealing equipment is shutdown as per standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
    Forming, filling and sealing equipment (Wet):
  • Bottle Fillers
  • Sachet Fillers
  • Barrel Fillers
  • Can Fillers
  • Pouch Fillers
  • Tray Fillers
  • Bag Fillers

    Forming, filling and sealing equipment (Dry):
  • Bottle Fillers
  • Can Fillers
  • Tray Fillers
  • Bag Fillers
     
    		•

    ASSESSMENT CRITERION 2 
    Unused raw materials and waste are recorded and handled as per standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
    Raw materials (Wet):
  • Glass Bottles
  • Plastic Bottles
  • Cans
  • Cartons
  • Sachets
  • Bags
  • Pouches
  • Trays
  • Barrels
  • Buckets
  • Cartridges
  • Tubs
  • In process product

    Raw materials (Dry):
  • Glass Containers
  • Pouches
  • Cans
  • Cartons
  • In process product
     
    		•

    ASSESSMENT CRITERION 3 
    Shift handover is performed as per standard operating procedure. 

    ASSESSMENT CRITERION 4 
    Deviations are identified, recorded and corrective action is taken as per standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
    Deviations:
  • Quality
  • Equipment
  • Operating and process deviations
     
    		•

    ASSESSMENT CRITERION 5 
    Health Safety and Environmental standards are adhered to as per legislation. 
    ASSESSMENT CRITERION RANGE 
    Includes:
  • Occupational Health and Safety Act
  • National Environmental Management Act
  • Company Standards such as NOSA, ISO 9002 and ISO 14000
     
    		•

    SPECIFIC OUTCOME 5 
    Prepare for and perform changeovers on forming, filling and sealing equipment. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Production plan is obtained and interpreted as per standard operating procedure before changeover is performed on forming, filling and sealing equipment. 
    ASSESSMENT CRITERION RANGE 
    Production plan includes the following information, volumes, brands, shift information, packaging requirements, production specifications.
     

    ASSESSMENT CRITERION 2 
    All the necessary tools, equipment, material and parts are prepared and available as per standard operating procedure. 

    ASSESSMENT CRITERION 3 
    Forming, filling and sealing equipment is changed over as per standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
    Forming, filling and sealing equipment (Wet):
  • Bottle Fillers
  • Sachet Fillers
  • Barrel Fillers
  • Can Fillers
  • Pouch Fillers
  • Tray Fillers
  • Bag Fillers

    Forming, filling and sealing equipment (Dry):
  • Bottle Fillers
  • Can Fillers
  • Tray Fillers
  • Bag Fillers
     
    		•

    ASSESSMENT CRITERION 4 
    Deviations are identified, recorded and corrective action is taken as per standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
    Deviations:
  • Quality
  • Equipment
  • Operating and process deviations
     
    		•

    ASSESSMENT CRITERION 5 
    Health Safety and Environmental standards are adhered to as per legislation. 
    ASSESSMENT CRITERION RANGE 
    Includes:
  • Occupational Health and Safety Act
  • National Environmental Management Act
  • Company Standards such as NOSA, ISO 9002 and ISO 14000
     
    		•


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
  • Anyone assessing a learner or moderating the assessment of a learner against this unit standard must be registered as an assessor with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA.
  • Any institution offering learning that will enable the achievement of this unit standard must be accredited as a provider with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA.
  • Assessment and moderation of assessment will be overseen by the relevant Education, Training, Quality, Assurance (ETQA) Body, or by an ETQA that has a Memorandum of Understanding with the relevant ETQA, according to the ETQA's policies and guidelines for assessment and moderation.
  • Moderation must include both internal and external moderation of assessments at exit points of the unit standard, unless ETQA policies specify otherwise. Moderation should also encompass achievement of the competence described in this Unit Standard. 
    		•

    UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
    Prepare and start forming, filling and sealing equipment:
  • Procedures for preparation and start-up of Forming, filling and sealing equipment.
  • Raw material: The Characteristics of Raw Material, the advantages and disadvantages of different raw material, the hardness, durability and rationale for the use of each packaging material utilised.

    Range: Raw materials (Wet):
  • Glass Bottles
  • Plastic Bottles
  • Cans
  • Cartons
  • Sachets
  • Bags
  • Pouches
  • Trays
  • Barrels
  • Buckets
  • Cartridges
  • Tubs
  • In process product

    Range: Raw materials (Dry):
  • Glass Containers
  • Pouches
  • Cans
  • Cartons
  • Wrapping
  • In process product

    Operate forming, filling and sealing equipment:
  • Procedures for the operation of Forming, filling and sealing equipment.
  • Role of the Forming, filling and sealing process in the packaging of food or beverages.
  • Basic understanding of graphs and algebra, statistical techniques for sampling, and monitoring of process control and quality.
  • Basic understanding of cost and budgets.
  • Understand the cost of wastage, understand variance analysis.

    Shut down forming, filling and sealing equipment:
  • Procedures for shut down of forming, filling and sealing equipment.

    Prepare for and perform changeovers on forming, filling and sealing equipment:
  • Procedures for preparation for and changeover of forming, filling and sealing equipment. 
    		•

    UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Identifying and solving problems in which responses display that responsible decisions using critical and creative thinking have been made. 

    UNIT STANDARD CCFO WORKING 
    Working effectively with others as a member of a team, group, organisation and community. 

    UNIT STANDARD CCFO ORGANISING 
    Organising and managing oneself and one's activities responsibly and effectively. 

    UNIT STANDARD CCFO COLLECTING 
    Collecting, analysing, organising and critically evaluating information. 

    UNIT STANDARD CCFO COMMUNICATING 
    Communicating effectively using visual, mathematical and / or language skills in the modes of oral and / or written persuasion. 

    UNIT STANDARD CCFO SCIENCE 
    Using science and technology effectively and critically, showing responsibility towards the environment and health of others. 

    UNIT STANDARD CCFO DEMONSTRATING 
    Understands the world as a set of related systems by recognising that problem solving contexts do not exist in isolation. 

    UNIT STANDARD CCFO CONTRIBUTING 
    Contributing to the full personal development of each learner and the social and economic development of the society at large by making it the underlying intention of any programme of learning to make an individual aware of the importance of:
  • Reflecting on and exploring a variety of strategies to learn more effectively.
  • Participating as responsible citizens in the life of local, national and global communities.
  • Being culturally and aesthetically sensitive across a range of social contexts.
  • Exploring education and career opportunities
  • Developing entrepreneurial opportunities. 
    		•

    UNIT STANDARD ASSESSOR CRITERIA 
    N/A 

    REREGISTRATION HISTORY 
    As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015. 

    UNIT STANDARD NOTES 
    This unit standard replaces unit standards:
  • 9056, which is " Operate and control aseptic forming, filling, and sealing of containers for food products", level 3, 18 credits.
  • 9130, which is "Operate and control the forming, filling and hermetic sealing of plastic sachets or bags for food products", level 2, 10 credits.

    Supplementary information

    Legal requirements:

    The following acts and/or codes, current and future regulations and amendments will be applicable:
  • Foodstuffs, Cosmetics and Disinfectants Act, No. 54 of 1972
  • Health Act, No 63 of 1977
  • Occupational Health and Safety Act, No. 85 of 1993
  • SABS Food Hygiene Management Code 49: 1989

    Definition of terms within this unit standard:

    Terminology: Clarification/explanation/definition:
  • Forming, filling and sealing equipment: An automated or semi automated machine on a packaging line that forms, fills and seals a package containing product.
  • Wet: Refers to an automated or semi-automated packaging process that contains a liquid product.
  • Dry: Refers to an automated or semi- automated packaging process that contains foodstuffs, spices and condiments that are solid.
  • Food products safety practices and procedures: Refer to good manufacturing practices, monitoring critical control points, HACCP's, practices against food product contamination and personal hygiene.
  • Standard operating procedures: Refer to company procedures, prescribed procedures from the manufacturer, personal and food product safety procedures, good manufacturing practices, best practices, applicable legislation, time frames, recipes and specifications. 
    		•

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Elective  80928   National Certificate: Confectionery (Chocolate, Sugar and Biscuit) Manufacturing  Level 3  NQF Level 03  Passed the End Date -
    Status was "Reregistered"     		 2023-06-30  FOODBEV 
    Elective  57694   National Certificate: Food and Beverage Packaging Operations  Level 3  NQF Level 03  Passed the End Date -
    Status was "Reregistered"     		 2023-06-30  FOODBEV 


    PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS UNIT STANDARD: 
    This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.
     
    1. Competence Performance Consulting (Pty) Ltd 


    All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.