Batch Preparation, Blending and Packing Procedure

Purpose. Describes how a batch of dry blended product is prepared, blended, tested, packed and recorded at Yatala and Townsville so that every batch matches the recipe and is fully traceable.

1.Scope

This procedure applies to all dry blended products made on the ribbon blenders and packed on the valve bag packer or the bulk bag station. It does not cover concrete batching at Bundamba, which is covered by the precast casting procedure. The procedure must be followed by operators, shift supervisors and laboratory staff.

2.Before starting

The operator must confirm the batch order number, product, recipe version and batch size on the production schedule. The blender, mill and packer must be clean and free of the previous product, confirmed by the changeover checklist. Dust extraction on the loading hopper and packer must be running and the pressure gauge must read within the green band. The operator must be wearing the fitted respirator required for the area.

• Batch order matches the schedule
• Recipe version is the current version in the recipe register
• Changeover checklist signed for the previous product
• Dust extraction running and gauge in the green band
• Scales checked with the daily check weight and recorded

3.Weighing and loading

Raw materials must be weighed on the calibrated batch scale in the order listed on the recipe. Each raw material lot number must be recorded on the batch record at the time it is loaded. Minor additives must be weighed on the bench scale and added through the additive hopper. The operator must not substitute a raw material without a signed authorisation from the Quality and Laboratory Manager.

4.Blending

The blender must run for the time stated on the recipe, measured from the moment the last raw material is loaded. The operator must record the start and stop times and any interruption. If the blender stops during the cycle, the operator must record the reason and restart the full blend time unless the laboratory approves a shorter time in writing.

5.Sampling and release

The operator must take the batch sample from the blender discharge using the sampling procedure and deliver it to the laboratory with the sample label completed. Packing must not start until the laboratory records a pass in the quality test register, except for products on the pre-approved list where packing can start and the batch is held in the quarantine bay until release.

6.Packing and pack weight checks

The packer operator must set the packer to the target weight on the product specification and check five bags at the start of packing and every 30 minutes on the check scale. Results must be recorded on the batch record. If the average is below the labelled weight or any bag is below the tolerable deficiency, packing must stop and the packer must be adjusted before restarting. Bags must carry the batch number and the packing date.

7.Completing the batch record

The operator must complete every field on the batch record before the end of the shift and the shift supervisor must review and sign it. The batch record must be entered in the batch and production log with the quantity packed, the number of pallets and any deviation. Incomplete records must not be signed off.

8.Deviations

Any departure from the recipe, blend time, sampling or weight requirements must be recorded on the batch record and reported to the shift supervisor before the batch continues. The shift supervisor must decide whether to hold the batch and must raise a nonconformance in the quality test register where the specification is affected.