Production Operator, Spray Dry - 2nd shift - Carthage

Purpose of Position

The Spray Dry Team Member I is an entry level position in the Spray Dry Division.The purpose of the position is to train and develop in efficiently operating all production areas in the Spray Dry Division.

Essential Responsibilities and Specific Duties

Safety

• Learn and comply with the safety procedures, regulations and policies of each spray drying area.
• Participate in all required safety training and programs
• Examples
• Lock-Out-Tag-Out procedure, grounding, handling of caustic material, proper lifting techniques, explosion suppression, and usage of respirators and other personal protective equipment (PPE).
• Notify leads, supervisors, or manager of safety incidents, and risks.

Quality

• Understand Spray Dry Quality programs and comply with procedures, and regulations.
• Understand the Z2 notification process.
• Understand and verify in-process quality checks.
• Record any quality deviations, and notify the lead, supervisor, or manager.
• Assist in Root Cause analysis for quality deviations.
• Understand and comply with the Spray Dry Food Safety program
• Understand the department HACCP plan
• Conduct and document HACCP checks (sieve, magnet, basket filter, and metal detector) as required
• Maintain accurate and consistent records of product run information.
• Assist in Root Cause investigations
• Understand and comply with Allergen program
• Ensure that equipment is clean before and after use and document cleaning parameters
• Ensure that items assigned on Master Sanitation List are completed and documented

Equipment/Process Knowledge

This position requires the ability to lift 50 lbs.Other requirements are to become proficient at using SAP software and understanding the production transactions and systems. Understand the principles, effects and impact on product of the six key areas of spray drying:batching, atomization, agglomeration, powder conveying, packaging, and cleaning.The Spray Dry Team Member must demonstrate adequate reading and writing skills, as well as be able to accurately perform basic math calculations.

Batching

• Ingredient Bill of Materials, and the basics of product families
• Order of addition
• Mix time and agitation requirements
• Heat effects on batching

Atomization

• Effects of feed temperature
• Feed pressure
• Percent solids
• Viscosity
• Nozzle size selection
• Control of feed rate

Agglomeration

• Control of inlet/outlet temperatures
• Maintaining correct dryer chamber pressure

Powder Conveying

• Airflow
• Product bulk density
• Cyclones, rotary valves, and powder dispensing

Packaging

• Gross/Net, and tare weights
• Understand customer requirements
• Effectively package and seal bags according to correct packaging requirements

Cleaning

• Understand operation of the CIP system
• Check key clean points (areas that are difficult to clean in the dryer)
• Kosher, allergen, odor, and acid washes

Equipment Used

The Dryer Team Member you will use the following types of equipment:

• Forktrucks
• Systems equipment (scanners, computers)
• Transfer pumps, High pressure feed pumps, portable drum pumps
• Portable drum mixers
• HMI control screens
• High and Low Shear Mixers
• Mill
• Scales
• CIP systems
• Bulk Pour dispensing systems
• Miscellaneous dispensing equipment

Job Specifications

Accountability

Responsible for product quality conforming to specification by following formula instructions, department procedures, and training.Productivity expectations are to be met while diligently following all safety procedures.

• Reports to Lead Spray Dry Team Member for assigned shift
• Performance is evaluated by:
• Safety (participation in safety programs, meeting required training, operating in a safe manner)
• Quality (consistently produces good quality product, follows process order instructions and order of addition)
• Productivity (kilograms of production, based on assigned area)
• Team Work (Co-operates with shift lead and other team members, maintains positive work attitude and work ethic)
• Attendance (reports to area on time)
• GMP Compliance (accurately follows documentation requirements, meets uniform requirements, follows allergen and cleaning requirements, follows Food Grade separation requirements)
• Teachability (demonstrates active participation in training programs and readiness to learn new areas; quickly demonstrates aptitude to Blending Processes and Systems; follows instructions and readily accepts constructive feedback; progresses through training according to established training plan)

Job Functions

• Pick and stage materials as needed; make batches as required
• Ensure equipment is clean before and after product runs
• Startup production runs
• Maintain efficient output of dryer during production run
• Package product according to customer specifications
• Ensure correct labeling is applied
• Clearly document production information as required:
• HACCP, (Critical) Control Point, and other Quality Checks
• Production operating parameters
• Properly document appropriate HACCP, Critical Control Point, and other Quality verification checks
• Packaging product as it is dispensed, into the correct container type
• Clean dryer (using CIP system or hand-washing)
• Maintaining a clean dryer room
• Assist Batch Team Member and Spray Dry Lead as needed
• Follow appropriate GMP requirements
• Assist and co-operate with Continuous Improvement ideas and projects