Coursework Questions Flashcards
1
Q
T/F Wheat is usually stored in the silo before any cleaning takes place
A
False
2
Q
… … is the term used to describe the process that takes place on the wheat after lab testing, before it enters the raw wheat silos
A
Preliminary Cleaning
3
Q
Select 2 options: Which can be termed ‘raw materials’
A) Flour
B) Wheat
C) Additive ingredients
D) Wheatfeed pellets
A
B) Wheat
C) Additive Ingredients
4
Q
Impurities removed during the process of wheat cleaning are collectively termed?
A) Wheatfeed
B) Bran
C) Screenings
D) Wheatfeed Pellets
A
C) Screenings
5
Q
Which 3 of the following would be considered finished products?
A) Wheat
B) Flour
C) Wheatfeed
D) Wheatgerm
E) Additive ingredients
A
B) Flour
C) Wheatfeed
D) Wheatgerm
6
Q
… is the term used to describe the process of mixing different base flours together to produce a different finished flour
A
Blending
7
Q
Label the flow of materials through the mill
A
1) Preclean
2) Conditioning
3) Gristing
4) Screenings
5) Ingredient addition
6) Despatch
8
Q
T/F Bulk storage bins are always made of steel
A
False
9
Q
Which 2 of the following statements are correct?
A) Concrete bins are easier to install and have lower maintenance costs
B) Steel bins can be used as soon as they are completed
C) Steel bins are usually heavier and require more foundation
D) Steel bins do not crack
A
B) Steel bins can be used as soon as they are completed
D) Steel bins do not crack
10
Q
Which 2 of the following statements are claimed advantages of packing from bulk bins
A) Cheaper to build than packing directly from the mill
B) Re-mixing considerations are not required
C) Less warehouse space is needed
D) Packing efficiency is improved
A
C) Less warehouse space is needed
D) Packing efficiency is improved
11
Q
List the advantages and disadvantages of packing from bulk bins as opposed to packing directly from the mill
A
Advantages:
1) Improved packing efficiency
2) Packing can be carried out as a daytime activity
3) Flour can be stored more hygienically
4) Less warehouse space is needed
5) White and brown flours can be packed on separate lines which avoids residual bran specks in product
6) Final redresser before packing can be used to safeguard from contamination
Disadvantages:
1) Attention is needed for the bin cleanliness
2) With more complex conveying, a certain number of bags packed when changing from one flour to another will need remixing as they would not be of the correct specification due to mixing with conveyors
3) High capital cost of bulk bins
12
Q
Which 2 factors could influence number and capacities of storage bins:
A) Cleaning budget availability
B) Labour availability
C) Capacity of mill
D) Co-products produced
A
C) Capacity of mill
D) Co-products produced
13
Q
Which 3 statements are correct when choosing square or circular bins
A) Cost
B) Personal preference
C) Space availability
D) Consideration of climate
A
A) Cost
B) Personal preference
C) space availability
14
Q
A mill produces a single flour at around 1000 tonnes per week and pelleted wheatfeed at 260 tonnes per week, how much storage capacity should be provided for flour and wheatfeed
A
Storage should be around 1 week for flour = 1000 tonnes, and 3-4 days for wheatfeed = 150 tonnes
Fewer larger capacity bins would be cheaper than multiple smaller capacity, for flour 7 x150 tonnes steel bins would be adequate
For wheatfeed, 4 x 40 tonne bins would be adequate
An argument could be made to have an extra bin so one bin could be used per vehicle outload.
15
Q
Which 2 of the following should be considered during bin design
A) Access for cleaning and internal surface treatment
B) Internal surface treatment and external temperatures
C) External temperature and number of bins
D) Minimum bin diameter and height
A
A) Access for cleaning and internal surface treatment
D) Minimum bin diameter and height
16
Q
Which 3 factors should be considered when designing access to bins
A) Should a safety grid be installed?
B) If top access is provided show large should the opening be?
C) Is the construction material concrete or steel?
D) Can access be provided from the bottom of the bin?
A
A) Should a safety grid be installed?
B) If top access is provided show large should the opening be?
D) Can access be provided from the bottom of the bin?
17
Q
Which 2 of the following statements should apply when considering the type of finish for the wall surface of a storage bin
A) Provision of a smooth wall surface for ease of product flow and cleaning
B) Whether the silo is constructed from steel or concrete
C) Whether any surface treatment is applied by spray or brush
D) Risk assessments associated with applying surface treatment
A
A) Provision of a smooth wall surface for ease of product flow and cleaning
B) Whether the silo is constructed from steel or concrete
18
Q
Which 3 of the following factors are essential to consider when choosing the correct hopper design:
A) Hopper slope angle is less than 60’ to the horizontal
B) Products discharge gradually across the full cross sectional area of the bin
C) Products are discharged evenly
D) Products cannot bridge across the hopper walls
A
B) Products discharge gradually across the full cross sectional area of the bin
C) Products are discharged evenly
D) Products cannot bridge across the hopper walls
19
Q
Summarise 4 main points you would consider if asked to design a bin for flour storage and why have they been considered
A
1) Bin diameter - Can determine whether bridging occurs, an important factor in spacing of the mill
2) Wall surfaces - Should be smooth to ensure material can slide down easily to maintain hygiene, and to keep it easy to clean
3) Access to bin - required for cleaning and maintenance
4) Height of bin - Limited by stresses induced by material in the hopper
20
Q
T/F Fluidised dischargers are never used on powdery materials
A
False
21
Q
Which 2 are advantages of using fluidised dischargers
A) They can be used with unfiltered air
B) They have no moving parts
C) They can empty a bin almost completely
D) They do not require oil free blowers
A
B) They have no moving parts
C) They can empty a bin almost completely
22
Q
Which of the following best describes the operation of evasser pads:
A) They inject air in 2 directions simultaneously, into the flour and onto the hopper wall
B) They inject air directly onto the hopper wall
C) They inject air directly into the hopper
D) They inject air firstly into the flour then onto the hopper wall
A
A) They inject air in 2 directions simultaneously, into the flour and onto the hopper wall
23
Q
Identify all 3 of the main types of mechanical dischargers
A) Vibrating discharger
B) Ribbon screw discharger
C) Twin worm discharger
D) Rotating barrel discharger
A
B) Ribbon screw discharger
C) Twin worm discharger
D) Rotating barrel discharger
24
Q
A ribbon screw disrcharger is ideally suited to which of the following products
A) Bran
B) Flour
C) Wheatfeed
D) Wheat
A
A) Bran
C) Wheatfeed
25
Describe the operation of a vibrating discharger and recommend the types of stock it can be used for
A vibrating discharger is operated on demand, not continuously.
Uses vibration to overcome material friction and promote flow of dry bulk materials from storage bins/silos
Shakes material to prevent bridging and sticking
A vibrating discharger can be used of floury stocks, additives, gluten increasers, and if specifically designed it can be used for wheatfeed and branny stocks
26
It is important to exhaust bins sufficiently in order to:
A) Prevent the bin from over-pressurising
B) Prevent dust escape
C) Help safeguard against potential dust explosion
D) Contain a dust explosion
A) Prevent the bin from over-pressurising
B) Prevent dust escape
C) Help safeguard against potential dust explosion
27
T/F Too much exhaust can lead to bin collapse
True
28
What 2 factors could influence the decision to adopt individual bin exhausts:
A) If a bin is used to store specialist products not for wide scale inclusion
B) If mechanical conveying is used
C) If a bin is situated remotely
D) If a bin is used for flour
A) If a bin is used to store specialist products not for wide scale inclusion
C) If a bin is situated remotely
29
Which type of bin content monitoring is considered to be the most accurate?
Load cells
30
Which type of bin content monitoring is easiest to retrofit to an existing bin
Ultrasonic level indicator
31
What is the first point to consider before allowing confined space entry?
Can confined space entry be avoided
32
T/F There are some instances when entry into a confined space does not require a risk assessment
False
33
Which 3 of the following factors should be considered before entering a confined space such as a bin:
A) All personnel must wear suitable PPE
B) Adequate emergency procedures must be in place
C) Nobody should enter a bin without a PTW
D) The emergency services should be informed beforehand
A) All personnel must wear suitable PPE
B) Adequate emergency procedures must be in place
C) Nobody should enter a bin without a PTW
34
Identify 3 factors that can influence the amount of dust and condensation within a bin
A) Method of conveying into the bin
B) Design of the exhaust system
C) Method of bin discharge used
D) Type of mill
A) Method of conveying into the bin
B) Design of the exhaust system
D) Type of mill
35
... ... can be used introduced into a bin to help minimise condensation
Dehumidified air
36
Summarise 5 key points to consider before allowing access into a confined space for bin cleaning. Provide a brief explanation about how you would achieve them
1) Avoid entry to confined spaces where possible - before entering space ensure that it is required
2) Where entry cannot be avoided, a safe system of work must be developed based of a risk assessment - make a risk assessment based on the cleaaning needed on that particular bin and create a safe system of work that must be adhered to
3) Always have a permit to work system for entry - ensure relevant worker has a permit to work for the bin cleaning needed
4) Ensure that adequate procedures for rescue and communication are documented, communicated and tested - ensure that the person that is required to carry out the work is informed of procedures
5) Ensure all people involved in confined space work are competent and adequately trained in relevant procedures
37
Which one of the following statements best describes the conditions required for a dust explosion to occur
A) When dust and air are compressed
B) When any amount of dust is present with a source of ignition
C) Only in enclosed spaces with dust and air present
D) when dust and air are present in the right mix and a source of ignition
D) when dust and air are present in the right mix and a source of ignition
38
What is usually controlled to prevent a dust explosion
Source of ignition
39
T/F For effective explosion relief any hot combustion gases must be able to vent to atmosphere or other safe area?
True
40
Which 2 of the following would be examples of preventing a source of ignition
A) Use of dust extraction and exhaust
B) Use of non-sparking tools
C) Prevention or control of any hot working practices
D) Use of explosion relief panels
B) Use of non-sparking tools
C) Prevention or control of any hot working practices
41
Explain how an explosion relief panel sealed by spring closure works
Explosion relief panels are kept in position by a spring closure, in which enough springs are attached around the edges to keep the bin dust tight, but they can give way when the pressure increases.
If there is an explosion in the bin, the panel is blwon off, which allows the force of the explosion to escape into the area above the bin, without bursting the bin. The panel should however be secured by a short chain so that it does not become a dangerous missile
42
List all the items within the mill that have explosion relief fitted, for each type provide a brief explanation of how they work
1) Elevators - flameless vents
2) General exhaust filters - explosion relief panel on filter to atmosphere
3) Pneumatic exhaust filters - explosion relief panel on filter to atmosphere
4) Grian storage silos - Proactive spark detectors, or reactive explosion relief panels at the top of the bin
5) Flour packing bins - Proactive spark detectors, or reactive explosion relief panels at the top of the bin
6) Positive pressure blowline - Explosion relief panel on filter receiver vented to atmosphere
43
T/F Introduction of peeling and debranning has compounded the difficulties of storing wheatfeed
True
44
Identify 3 factors that can increase the difficulty of storing wheatfeed
A) High humidity
B) Use of soft wheats in the mill
C) High temperature
D) Moisture contents above 14.5%
A) High humidity
C) High temperature
D) Moisture contents above 14.5%
45
T/F Continuous turnover of wheatfeed should be practiced if storing wheatfeed for any length of time
True
46
identify 3, which types of discharger could be used for wheatfeed
A) Multiple worm dischargers
B) Vibro dischargers
C) Twin worm dischargers
D) Fluidised dischargers
A) Multiple worm dischargers
B) Vibro dischargers
C) Twin worm dischargers
47
... ... Is the scheme that covers assurance standards for the supply of feed materials
FEMAS - Feed materials assurance scheme
48
Compare advantages and disadvantages between use of mechanical and vibro-dischargers for wheatfeed bins, consider cost, simplicity and hygiene
Vibrating dischargers are one of the cheaper systems to install, and cheap for a low discharge rate as it is operated on demand so is not required to be on constantly, but with higher rates it can become expensive. It is also not very efficient with bulk products that are sticky.
Mechanical dischargers are goof as they do not need vibrating or compressed air to function, which saved running costs, but they do require a greater upfront cost. The product can be discharged evenly at high rates
Vibro dischargers empty completely, but mechanical dischargers always have wheatfeed in the bottom.
49
A ... ... is the name given to the system that used one filter to exhaust several bins
Central exhaust
50
Describe 2 ways to help ensure the consistency of finished products
1) Select and grade wheats that are then mixed together to form a grist, then mill the grist to produce the required flour
2) Select and grade wheats that are milled individually, the flour formed from that are then mixed in the correct proportions to produce the required flour
51
Which of the following statements are true of a continuous blending and mixing plant
A) It is a cheaper simpler option than batch blending systems
B) Ingredients need to be manually added
C) It uses a mixer on load cells
D) It is a form of gravimetric blending
A) It is a cheaper simpler option than batch blending systems
D) It is a form of gravimetric blending
52
What are the differences between gravimetric and volumetric blending systems:
A) Volumetric addition is based on the volume of the product whilst gravimetric addition is based on actual weight of product
B) Volumetric and gravimetric are the same
C) Volumetric addition accuracy is affected by differing product density values
D) Volumetric addition is more accurate than gravimetric addition
A) Volumetric addition is based on the volume of the product whilst gravimetric addition is based on actual weight of product
C) Volumetric addition accuracy is affected by differing product density values
53
What type of blending system is shown in the diagram
Weigher and mixer system
54
What statements describe a weigher and mixer blending system
A) The mixer is the weigher
B) The weigher/mixer system has a greater throughput than a weighmix system
C) The ingredients are weighed into separate hoppers before being transferred into the mixer
D) Mixing cannot start until all ingredient components are weighed out
B) The weigher/mixer system has a greater throughput than a weighmix system
C) The ingredients are weighed into separate hoppers before being transferred into the mixer
55
A weighmix system consists of
A weigher on loadcells that act as both weigher and mixer
56
A homogeniser is designed to:
A) Mix together all required ingredients to produce a consistent flour by batch
B) Mix together all the required ingredients to produce a consistent flour on a continual basis
C) Mix together some of the ingredients by batch
D) To provide a means to collect flour before conveying to storage bins
B)Mix together all the required ingredients to produce a consistent flour on a continual basis
57
What are the disadvantages of a typical weighmix batch blending system and a continuous blending system
Batch disadvantages
1) High capital cost
2) High energy and maintenance costs
3) Increased amount of 'rework' if there are not separate systems for white and brown flours
Continuous disadvantages
1) Accuracy at very start of job
58
Advantages of batch and continuous blending systems
1) Blending evens out inconsistencies found during milling
2) Individual wheats can be milled and stored separately
3) Out of spec flours can be brought back into spec by blending with different base flours
4) Consistent final flour protein and finished product
5) No ingredient addition on the mill
6) Smaller range of base flours can produce large number of finished flours
7)Can be automated to minimise supervision
8) Flexibility
9) Custom made flours can be produced easily
10) Production of ready mix value added flours
59
What quality control equipment can be added between mixing and packing/bulk outloading to ensure product credibility
A) In-line NIR analysis
B) Redressers
C) In-line sterilators
D) Metal detection
E) Start up hopper
B) Redressers
C) In-line sterilators
D) Metal detection
60
What method of conveying is the most widely used method of transferring products to packing?
Pneumatic conveying
61
T/F Magnets remove any unwanted ferrous metals?
True
62
Why is a redresser used in the packing section?
A) To remove all impurities present
B) To remove only cereal impurities
C) To remove cereal or non-cereal impurities larger than the aperture size of the screen fitted
D) To ensure the removal of large impurities
C) To remove cereal or non-cereal impurities larger than the aperture size of the screen fitted
63
What size aperture is commonly used on a white flour redresser
1mm
64
What are widely used in electronic weighers to convert weight into an electrical signal?
Load cells
65
Describe the 2 types of arrangement to a packing weighing scale
1. 2 speed screw - 2 speed motor driving a worm, the high speed gives fast coarse bulk and the slow feed tops up the rest of the weight more accurately
2. Double screw feeder - 2 separate screws, one a coarse high volume feed, the other a in low volume feed, both feeding into the scale bucket
66
Select 2 pieces of legislation relevant to flour packing
A) Consumer protection act 2007
B) Food safety act 1990
C) Weights and measures act 1985
D) Weights and measures regulations 1986
C) Weights and measures act 1985
D) Weights and measures regulations 1986
67
A packing system designed to ensure the bag contents weigh at lest the weight stated on the bag is known as
A minimum weight system
68
Which statements apply to the term Tolerable Negative Error
A) No bag must exceed the TNE
B) It is used on a minimum weight system
C) It is used on an average weight system
D) TNE is a set amount below the nominal quantity of weight of the bag
E) No bag must exceed twice the TNE
C) It is used on an average weight system
D) TNE is a set amount below the nominal quantity of weight of the bag
E) No bag must exceed twice the TNE
69
Explain the three packers rules
1) The actual contents of the bags should not be less than the nominal quantity
2) The proportion of bags having a negative error greater than the TNE must be sufficiently small for the batches of bags to satisfy the requirements in schedule 2 of the regulations
3) No bag may have a negative error larger than twice the specified TNE. Automated checkweighers would reject any bag over twice the specified TNE.
70
What is meant by the term 'Give away'
Term used to describe the difference in weight between the minimum weight required for a bag, and the marginally heavier weight that the weigher is set to to take into account any inaccuracies of the scale and moisture loss in sotrage.
71
In a typical packing process, identify all item installed specifically for product protection reasons, and state the impurities removed
Magnets - before a perforated metal screen redresser, a magnet removes ferrous metals so they do not enter the redresser and damage equipment, after a perforated screen, a magnet ensures any ferrous metals that may have come from a damaged screen in the event of screen failure are removed
Redressers - remove any non cereal and cereal related foreign material larger than the installed sieve aperture so it does not end up in the final product
Metal detectors - remove any ferrous and non ferrous metals that may be within a bag so they do not go out to customers
72
Which type of packers can be used in a flour mill
A) Multi-valve packer
B) Valve packer
C) Single spout open mouth packer
D) Multi spout open mouth packer or carousel
B) Valve packer
C) Single spout open mouth packer
D) Multi spout open mouth packer or carousel
73
What are disadvantages of the valve packer
A) Inaccurate weighing is more likely
B) Bag stitching is necessary
C) Sacks are more expensive because of their more complex construction
D) Possing is necessary
A) Inaccurate weighing is more likely
C) Sacks are more expensive because of their more complex construction
74
What type of packer would you select for accurate weighing of bags at up to 800 bags per hour
Multi-spout open mouth packer or carousel
75
Bag placers are used on a packing line to
A) Select a suitable design of bag
B) Ensure the bag has the correct printing
C) Automatically place a bag on the filler spout of the packer
D) Supervise packing machine
C) Automatically place a bag on the filler spout of the packer
76
Why is possing used and how can it be acheived
Possing is the process where a filled bag is shook violently to make the flour settle and not be aerated and bulky. It can be achieved by an electric motor driving an eccentric shaft with a ribbed face on the end that beats a filled sack which moves flour down the sack
77
T/F Gluing of stitching can be used to close bags
True
78
Describe 3 ways to stitch bags closed and consider the advantages and disadvantages
1) Strip of crepe tape folded over the top of the bag and the bag top cut clean by a pre-cutter. Stitcher then stitches the top edge of the bag through the crepe tape, which has the advantage of a neat finished end, disadvantage of being costly in terms of crepe and produces a lot of waste paper
2) Top of bag can be folded over as it enters the stitcher, the stitcher then stitches through the folded section of the bag giving a well sealed closure. Disadvantage of being costly because of additional bag length required and because the needle needs to be cooled by a blast of compressed air to prevent heat stress breakage
3) Stitching without crepe or folding the top of the bag, advantage of being cheap, but flour can seep through the stitching when the bag is handled
79
Why must bags be coded clearly
A) To enhance aesthetic appeal
B) To enable traceability
C) Compliance with safety regulations
D) To enable stock control
B) To enable traceability
D) To enable stock control
80
What is the purpose of an in-line check weigher
Designed to weigh all bags before palletisation so any under or over weight bags are rejected
Last bag weigh check in process
Can be programmed to stop the line
Control panel has pre-programmed min and max weight values
81
What applies to the requirements of the food information regulations
A) The label should contain information regarding allergens
B) The label should not mislead the consumer as to the nature of the product
C) The label should always be clear and legible
D) The label should always be placed at the bottom left hand corner of the packaging
A) The label should contain information regarding allergens
B) The label should not mislead the consumer as to the nature of the product
C) The label should always be clear and legible
82
State 5 things that should be included on a good label for a baked product
1) List of ingredients
2) Quantity of certain ingredients
3) Special storage conditions
4) Instructions for use
5) Nutrition declaration
83
Why are metal detectors used in packing lines
Can detect any ferrous and non ferrous metals that are within the machines sensitivity range that might be in a bag.
It would stop the conveyor that the bag was on and sound an alarm or activate a diversion system to reject the bag
This stops any product containing metal being sent out
84
What of the following are true of metal detectors
A) A metal detector will remove only non-ferrous metals
B) The strength of signal generated by a metal detector is affected by the type of metal contaminant
C) A metal detector will remove ferrous and non-ferrous metals within the sensitivity range of the detector
D) A metal detector will remove all non-ferrous metals
B) The strength of signal generated by a metal detector is affected by the type of metal contaminant
C) A metal detector will remove ferrous and non-ferrous metals within the sensitivity range of the detector
85
What factors might affect the testing frequency of a metal detectos
Testing frequency should be set to ensure efficient product recall and re-work. Packer capacity and warehousing techniques should be considered
86
What is true of the following statements regarding sacks
A) Sack design should consider prevention of infestation ingress
B) The most common sack size in 2023 is 16kg
C) Sacks are always made from paper
D) Sacks can account for up to 5% of the flour sale price in the UK
A) Sack design should consider prevention of infestation ingress
B) The most common sack size in 2023 is 16kg
D) Sacks can account for up to 5% of the flour sale price in the UK
87
Identify and describe 6 factors to consider when designing sacks
1 - customer requirements
2 - Handling
3 - Packing
4 - Sack size
5 - Closed end design
6 - Method of closure
88
What material are FIBCs usually made from
Polypropylene
89
Select 2 reasons why intermediate bulk containers have become popular
A) Reduced milling temperature
B) Reduced chance of contamination from paper and string
C) Enhanced flour flavour
D) Minimal capital investment
B) Reduced chance of contamination from paper and string
D) Minimal capital investment
90
What is correct of FIBCs
A) FIBCs can have a polythene lining if required
B) FIBCs do not require possing during filling like 16kg bags
C) Lines FIBCs do not require any inflating before use
D) FIBCs can be up to 1 tonne in capacity
A) FIBCs can have a polythene lining if required
D) FIBCs can be up to 1 tonne in capacity
91
How can FIBCs be filled
1 - weigh the flour into the bag by means of a packing scale
2- weighing the bag as it is being filled from a 2-speed screw conveyor or discharger with the bag resting on a load cell weigh platform
Possing is essential to remove trapped air. This can be done automatically by a vibrating platform. 1 operative should be capable of fitting the bag on the spout, filling it, typing it off, removing it with a forklift truck
92
What are the disadvantages of manual palletisation
1. High labour costs
2. Pallets produced are unstable which produces stacking safety concerns
3. Pallets produced are untidy and poorly presented to the cutomer
4. Manually stacked pallets cannot be stacked more than 3 high, so there is a loss of warehouse space
5. High task repetition can potentially cause musculoskeletal disorders
93
Which stacking types are usually used on standard 1000mm x 1200mm pallets?
A) Chimney 4
B) 3 and 2
C) Chimney 8
D) 3
E) 3 and 2 with spacing
F) 2 and 1
A) Chimney 4
B) 3 and 2
C) Chimney 8
E) 3 and 2 with spacing
94
Identify each type of stacking
1) 2 and 1
2) 3 and 2
3) 3 and 2 with spacing
4) 3
5) Chimney 4
6) Chimney 8
95
What is true of automatic palletisation
A) Pallets produced can be unsafe
B) Initial capital outlay is high
C) A bag flattener is required to shape the bag prior to palletisation
D) Labour costs are high
B) Initial capital outlay is high
C) A bag flattener is required to shape the bag prior to palletisation
96
What are the advantages of automatic palletisation
1. Uniform presentation, provides stability and safe block stacking, also maximises space in the warehouse and provides a more stable load on the delivery vehicle
2. Presentation is tidier which gives a better impression to customers
3. High throughput
4. Stacking patterns can be altered
5. Packing and palletising can both be controlled by one operative and a forklift truck driver, which also makes for quick changes from one product to another
6. Reduced labour costs
97
What are disadvantages of automatic palletisers
A) Stacking patterns are easily changed on programmable control
B) Can occupy a large area, reducing storage space
C) Automatic palletisers require high maintenance attention to maintain efficiency
D) Reduced labour costs
B) Can occupy a large area, reducing storage space
C) Automatic palletisers require high maintenance attention to maintain efficiency
98
The efficiency of a pallet dispenser depends on the '....' of the pallets
Quality
99
Which of the following materials are commonly used to make pallets
A) Plastic
B) Aluminium
C) Wood
D) Steel
A) Plastic
C) Wood
100
What is involved in the operation of a typical pallet inverter and what is a pallet inverter used for
The operation of a pallet inverter involves:
1. Using a fork truck, place stack with pallet on the bottom plate of the inverter, and place a new pallet on top of the stack
2. Clamp the top plate down onto the stack and turn it 180'
3. When the load has been inverted 180', unclamp and lift out the stack
A pallet inverter is used to:
1. Turn stacks of bags to replace damaged bags in the bottom of intermediate layers of a stack
2. Rapid replacement of damaged pallets
3. Fast and convenient exchange between unclean wooden pallets and clean plastic pallets
4. Compression/straightening of stacks
5. Place or remove slip sheets
6. Using plastic protection bags to cover top and bottom of the stack to make it watertight
101
What points should be considered when selecting the type of pallets to be used in a warehouse operation
1. Size of pallet required
2. Whether 2 or 4 way truck entry is needed
3. Whether they should be reversible or not
4. Whether they should be close or open board
5. The weight of the load to be carried
6. The material they are to be made of
7. The method of mechanical handling
8. The method of stacking
9. Quantity required
10. Customer requirements
102
What should be considered to prevent product damage on a pallet?
A) Pallets should not be block stacked to prevent damage to product
B) All bags should be interlocked
C) Pallet slats should be in good condition
D) Slip sheets must be used between the pallet and the bottom layer
B) All bags should be interlocked
C) Pallet slats should be in good condition
D) Slip sheets must be used between the pallet and the bottom layer
103
Identify 3 main factors that must be taken into consideration when designing a warehouse building
1. land space available
2. Storage requirements
3. Labour force required
104
List 5 reasons why single story warehouses are generally preferred to multi story warehouses
1. Cheaper to build than multistory because they can have lighter foundation and no need for strong floors or extra supports
2. Quicker build time
3. Can be purpose built to allow for:
Easy transfer of stocks from packing are
Minimal structural intrusion in working areas
Safe and quick operation of modern forklifts and other handling equipment
Easier installation of pallet racking
4. Allows for maximum space
5. Cost of increased height is not prohibitive
105
T/F Single story warehouses are usually more cost effective than multi-story warehouses
True
106
Select 2 factors that may lead to selection of a multi-story warehouse
A) A limitation on available land space
B) Construction should be steel and cladding
C) A large storage capacity is required
D) A quick build time is required
A) A limitation on available land space
C) A large storage capacity is required
107
Which of the following factors should be considered when designing the layout of a warehouse?
A) Type of lighting used
B) Safety issues associated with pedestrian routes
C) Racking colour
D) A workable FIFO system
B) Safety issues associated with pedestrian routes
D) A workable FIFO system
108
Identify and explain the factors you would consider when determining warehouse storage requirements
1. Atmospheric conditions relating to products
2. Price fluctuations of products
3. Warehouse design for stock rotation allowance
4. Method of storage should minimise risk of damage to product
5. Minimisation of risk of infestation
6. Space should be allowed for bought in products and any mill additives stored
7. The space required for picking and marshelling loads
8. Space for equipment and tricks to be operated safely
9. Sufficient accommodation for chosen method of loading vehicles
10. Suitable isolation area for complaints, out of date products etc
11. If FIBC packing is a requirement then suitable space for equipment and storage should be considered
109
List 3 methods of storing pallets
1. Single pallet high stack
2. Block stacking
3. Pallet racking
110
Storing pallets one on top the other is known as
Block stacking
111
What are the advantages of block stacking
A) Good use of available space
B) Flexibility in warehouse layout
C) Pest control and cleaning are easier
D) Easy facilitation for storage of part filled pallets
A) Good use of available space
B) Flexibility in warehouse layout
112
List 5 disadvantages of block stacking pallets
1. Limited height as there is a lot of pressure on the bottom layer
2. Pallets in the middle and bottom of the stack are not easily accessible
3. Increased risk of damage to products
4. Difficult to block stack incomplete pallets
5. Pest control and cleaning is more difficult
113
Why is it necessary to fit a guard to the front upright leg of pallet racking?
A) To provide structural support to the racking
B) To protect forklift trucks from incurring damage
C) To protect upright legs from forklift damage
D) To prevent product damage
B) To protect forklift trucks from incurring damage
114
List 3 considerations when choosing pallet racking as a method of storing pallets
1. It should be capable of bearing the weight of the heaviest pallet that will be stored
2. It should have sufficient width to allow forklift access between pallet support rails with sufficient support for the pallet to allow for slight flexing
3. The front upright legs of the racking should be fitted with short steel guards to prevent accidental and potentially serious damage to the rack by the forklift wheels
115
What 2 factors must be considered when stacking IBCs
A) They cant be block stacked
B) An IBC is not as stable as a pallet of bagged flour
C) They cant be stored in racking
D) Ensure pallets are strong enough to store in racking
B) An IBC is not as stable as a pallet of bagged flour
D) Ensure pallets are strong enough to store in racking
116
What is true: The choice of FLT type is dependent upon:
A) Space available
B) The running costs
C) Capital costs
D) All of the above
D) All of the above
117
What are the 2 main types of powered FLT usually seen in flour warehouses
1. Reach trucks
2. Counter balance trucks
118
What are the advantages of reach trucks
A) They offer greater flexibility than counter balance trucks
B) They are more stable than counter balance trucks
C) They can be gas, electric or diesel powered
D) Increased storage space due to narrow operating ability of reach trucks
B) They are more stable than counter balance trucks
D) Increased storage space due to narrow operating ability of reach trucks
119
What are the advantages of counter balance trucks
A) They can carry heavy loads over long distances
B) They can work on a variety of surfaces
C) They can operate in very narrow aisles
D) They help reduce driver fatigue if frequent reversing is required
A) They can carry heavy loads over long distances
B) They can work on a variety of surfaces
120
List 7 safety devices that can be seen on FLTs
1. Warning light
2. Audible/visual reversing alarms
3. Speed limiters
4. Seat belt inhibitors
5. Weight indicators
6. Camera systems
7. Fleet monitoring systems
121
What is the cheapest type of FLT
Hand pallet truck
122
The recommended requirements for FLT drivers include:
A) Good eyesight, general health and be over 18 years of age
B) Smart overall appearance and be over 18 years of age
C) Possession of a valid car license
D) Good eyesight and short hair
A) Good eyesight, general health and be over 18 years of age
123
When using gas powered FLTs, what are the signs and symptoms of carbon monoxide poisoning and name 3 ways to prevent this?
signs and symptoms:
1. Dull headache
2. Weakness
3. Dizziness
4. Nausea or vomiting
5. Shortness of breath
6. Confusion
7. Blurred vision
8. Loss of consciousness
3 ways to prevent this:
1. Adequate ventilation to prevent build up of fumes
2. Regular carbon monoxide testing
3. Effective vehicle maintenance
124
Which type of truck is most suitable for general warehousing when space is a premium
Reach
125
List 10 daily checks that must be completed on an FLT before use
1. Faults from the previous day
2. Obvious leaks
3. Hydraulic fuel level
4. Mast and carriage damage check
5. Forks checked for cracks
6. Backrest/extension checked for damage or debris
7. Tyres wheels and nuts checked for damage
8. Steering checked for any unusual movement
9. Correct operation of warning lights. gauges or instruments
10. If the operating system is initialised and works
126
Which truck is most unsuitable for loading from an uneven surface?
Reach truck
127
Describe the considerations associated with drivers and their use of powered FLTs in the working environment. Consider FLT selection, people requirements and site safety considerations
Type of forklift truck should be selected with the requirements, driver and site in mind. e.g. on the site if there is not a lot of space available to manoeuvre, then a reach truck should be selected. If there is load marshalling then a counterbalance or reach truck could be used. For loading then things like road surface and speed need to be taken into account, if the loading is done from ground level on an even surface then a counterbalance truck can be used, if the ground is uneven then a reach truck cannot be used, if loading is happening from a raised platform then a pedestrian truck can be used.
The driver must be considered, they must be over 18, fit, have good eyesight, hearing and reflexes and be trained and licensed in safe operation of the truck, how the truck works, the load capacities and principles of balance and the stacking and de-stacking techniques. They should have a refresher course every 3 years.
Drivers should be aware of site safety considerations such as keeping keys to the FLT secure when not in use, no passengers on the FLT, never park the FLT with the forks raised and the operator needs to be aware of the signalling and traffic systems on site.
128
What can be used to help improve and maintain warehouse efficiency
WMS - Warehouse Management System
129
Describe 2 things that are necessary to ensure successful implementation and maintenance of a WMS
1. Training personnel
2. Ensuring that competence does not disappear through staff changes or lack of application
130
Why is it necessary to have accurate stock control
It is essential to the financial control of the business and vitally important to the day to day operation of the mill and its production requirements
131
What should be done with open or damaged bags of returned goods
They should be disposed of regardless of the reason for return
132
Bag codes are primarily used for:
A) Ensuring compliance with weights and measures
B) Tracking and monitoring of goods in the warehouse
C) Ensuring the correct bag has been selected for a product type
D) It gives ingredient information
B) Tracking and monitoring of goods in the warehouse
133
Methods of filling bulk flour tankers include
A) From a blowline direct to the tank top hatch
B) Discharge of fluidised flour in a bin directly into a tanker
C) Via a mechanical discharger
D) Conveyors discharging directly into a bulk tanker
B) Discharge of fluidised flour in a bin directly into a tanker
D) Conveyors discharging directly into a bulk tanker
134
Describe a method of bulk filling flour tankers which would be the quickest
Direct from an outload bin above the vehicle by lfuidising the lfour with air and releasing the flour into the hatch near the centre of the tank. The flour flows at a high rate of about 250-300 tonnes per hour
135
Describe the type of bulk outloading shown
The diagram shows a system in which flour is pre-weighed in a large weigh tank on load cells with a fluidised bottom. It is then fed, via fluidised conveyor, into the single hatch of the vehicle. The load speed is about 20 tonnes in 4 mins.
136
What are the 8 points to consider when loading a bagged flour
1. Vehicle is confirmed fit for use before loading
2. Correct stock has been identified and certified by the laboratory and loaded
3. Product quality has been preserved by using correct handling techniques
4. Items checked and recorded as they are loaded
5. Goods are loaded in the correct sequence
6. Operation is carried out safely and in minimum times
7. Load is secure at all times
8. Delivery documents are available
137
Match the correct weight and axle combination
1 18t, 2 axle rigid
2. 26t, 3 axle rigid
3. 40t, 5 axle articulated
4. 44t, 3 axle unit, 3 axle tanker
138
Identify which two of the following co-products are usually delivered in bulk
A) Loose wheatfeed
B) Bran for human consumption
C) Pelleted wheatfeed
D) Wheatgerm
B) Bran for human consumption
D) Wheatgerm
139
Which of the following are typically involved in the process of multi-drop deliveries
A) A 'load plan' is created based on the delivery schedule
B) Drivers organised their own routed by experience
C) The warehouse PC generates delivery documents and informs the transport department that the vehicle is loaded
D) The driver manually enters the vehicle registration and quantities into the warehouse PC
A) A 'load plan' is created based on the delivery schedule
C) The warehouse PC generates delivery documents and informs the transport department that the vehicle is loaded
140
What would you consider when designing a suitable WMS
Size of operation
Amount of stock held
Range of products
Type of warehouse
Layout and methods of stacking
Speed and ease of operation
Labour availability
Potential cost saving
Vehicle size and type
141
What are the 6 rights of logistics
the right goods in the
right quantities in the
right condition delivered to the
right place at the
right time for the
right cost
142
How many major elements are there in the logistics cycle
5
143
Briefly describe the logistics cycle
The cycle is circular as the elements are cyclical or repetitive in nature.
The elements of the cycle are:
serving customers,
product selection
quantification and procurement
inventory management
storage and distribution.
All these elements are dependent on and affected by other elements.
The activities in the centre of the cycle (LMIS, pipeline monitoring, organisation and staffing, budgeting, supervision and evaluation) represent the management support functions that inform and impact the other elements around the logistics cycle.
144
Determining how much product to deliver to a customer would fall within which of the following elements of the logistics cycle?
Quantification
145
List and explain 4 activities that help drive and support the logistics cycle
1) Organisation and staffing - well trained, efficient staff need to monitor stock levels, place orders and provide products to customers
2) Budget - Allocation and managmenet of finances directly affect all parts of the logistics cycle
3) Supervision - Supervision of staff keeps it running smoothly and helps anticipate required changes
4) Monitoring and evaluation - Routine monitoring and periodic evaluation of activities help demonstrate how well the system is performing and the areas that can be improved
146
When determining supply chain costs, logistics managers should consider
A) Transport costs
B) The cost of vehicle depreciation
C) Storage, transportation and management costs
D) Storage costs
C) Storage, transportation and management costs
147
In addition to customer requirements, and any losses and adjustments, what other essential data would the logistics manager need to make informed decisions
A) Wheat stocks
B) Latest bin cleaning requirements
C) Mill extraction reports
D) Current stock levels
D) Current stock levels
148
What 3 rights of logistics are covered by the transport manager
Delivery to the right place at the right time in the right condition
149
Does a transport manager have to be employed directly by an organisation? YES/NO
No
150
What can the transport manager use to demonstrate driver compliance to the EU Working Time Directive
Tachograph data
151
How many hours per week would a transport manager be expected to work if managing a fleet of up to 17 vehicles
20-30 hours per week
152
List 5 good vehicle maintenance system components
1 A daily walk round check by dirvers before the vehicle and where appropriate, the trailer are taken out
2 Regular preventative maintenance inspections
3 Pre-planning of inspections, using a flow chart or some method that ensures that inspection dates are not missed
4 A written driver defect-reporting system
5 Communication between management, drivers and workshop staff
153
Identify why DCPC was introduced
A) Driver reduction
B) Maintain professionalism within the industry
C) Increase fuel efficiency
D) Improve road safety
B) Maintain professionalism within the industry
D) Improve road safety
154
How long is the DCPC qualification valid for before re-testing need to take place
5 Years
155
It is the responsibility of ... to ensure DCPC driver training is up to date
The driver
156
In order to maintain a DCPC how many hours of periodic training per 5 years is required
35
157
Summarise the employer and employee duties associated with the role of the transport manager
Employer duties:
1) Properly qualified and experienced transport manager is appointed
2) Transport manager effectively and continuously manages the transport activities
3) Transport manager has a genuine link to the undertaking expressed in either a formal contract of employment or a contract for services
4) Sufficient time is allowed in relation to the number of vehicles operated for the proper performance of the duties of the transport manager and that additional assistance is provided when indicated
5) Decisions and policies made by transport manager relating to transport activities are not overridden
Employees duties:
1) Mange, audit, review compliance systems to ensure that they are effective
2) Review any shortcomings such as prohibitions and/or annual test failures
3) Ensure that relevant changes are notified in accordance with operator licence requirements
4) Keep up to date on relevant changes in standards and legislation
5) Ensure drivers hold the appropriate entitlement for the vehicle they are driving
158
What should be considered before arranging bulk or bagged flour deliveries
A) Knowledge of vehicle routes and delivery points
B) Legal requirements
C) Environmental issues
D) Customer specific delivery requirements
E) Shelf life
F) Storage capacity
A) Knowledge of vehicle routes and delivery points
B) Legal requirements
C) Environmental issues
D) Customer specific delivery requirements
F) Storage capacity
159
When arranging flour deliveries, which of the following would be environmental considerations
A) Driver working hours
B) noise considerations when unloading
C) Vehicle routing
D) Time taken to deliver
B) noise considerations when unloading
C) Vehicle routing
160
Why are bulk deliveries weighed before leaving site
A) Compliance to pressure regulations
B) For stock control purposes
C) For quality control
D) To ascertain the weight
B) For stock control purposes
D) To ascertain the weight
161
Which materials are usually used for tank manufacture
A) Wood
B) Steel
C) Bronze
D) Aluminium alloy
B) Steel
D) Aluminium alloy
162
List 3 things that would influence the delivery blowing pressure
1) Vehicle type
2) Sites safe operating procedure
3) Distance between the end of the vehicle and customers silo
163
Define the term ullage
The usable volume available within a silo to accept the flour delivery
164
After discharge and before weighing out from site, what 2 items should a driver ensure and why
1) the tank is completely empty
2) any pressure in the tank should be released
Ensures there is no pressure contained in the tank when travelling on the public highway and so that it is safe to open the hatches for refilling upon its return to the mill
165
What are 2 types of compressors used to create the air pressure in tank before offloading
1) Tractor unit/tanker
2) Land-based blower
166
Where should the keys to a parked tanker never be left
In the parked tanker
167
What are 5 safety aspects associated with bulk vehicle unloading and why are they important
1) When attempting to carry out any vehicle manoeuvre, drivers should carry out a thorough visual check of the area
2) Drivers should ensure that all reversing alarms/bleepers, cameras and hazard warning lights are switched on before carrying out any/all vehicle manoeuvres
3) Never leave a vehicle unattended whilst discharging
4) Check the pressure relief valve is operational
5) The appropriate PPE for the task should be provided and used
168
What 5 records should be kept post any scheduled cleaning
A) The physical conditions where infestation occurs
B) Deficiencies in proofing against pests
C) Cleaning checklist
D) The sighting and treatment of infestation
E) Maintenance report
F) Recommendations and action taken for immediate and future preventative measures
G) Housekeeping 'failures' in any areas of the silos, mill and warehouses
H) Inventory usage record
A) The physical conditions where infestation occurs
B) Deficiencies in proofing against pests
D) The sighting and treatment of infestation
F) Recommendations and action taken for immediate and future preventative measures
G) Housekeeping 'failures' in any areas of the silos, mill and warehouses
169
Chemical treatments in the form of insecticides are defined into what two types?
A) contact
B) Mist sprayed
C) Residual
D) Systemic
A) contact
B) Mist sprayed
170
Contact insecticides offer some protection against what type of infestation
Confused flour beetle
171
Describe 3 limitations of contact insecticides
1) Thermal fogging, smoke generators and mist spraying will kill moth adults exposed to the insecticide particles, but have little effect on moth populations unless treatment is carried out frequently and insecticidal deposits only last a short time
2) Many insect pests breed and lay eggs deep in the flour, therefore the larvae and pupa are not exposed to the airborne droplets or those that land on the horizontal surfaces
3) High standards of hygiene are necessary if surface insecticidal treatments are to be of any value in controlling crawling insects
172
Contact insecticides should never
Come into direct contact with foodstuffs
173
Pheremones are used as a means to ... moth and beetle infestation
Monitor
174
Identify 7 steps of an IPM
1) Inspection
2) Preventative action
3) Identification
4) Analysis
5) Treatment selection
6) Monitoring
7) Documentation
175
Identify all the methods that can be used for rodent control
A) Trapping
B) Poisoning
C) Gassing
D) Shooting
A) Trapping
B) Poisoning
C) Gassing
176
Identify 4 types of rodent poison
1) Anticoagulents
2) Alphachloralose
3) Calciferol
4) Contact dusts
177
... is a type of poison suitable for use in areas that are difficult to access and are not near grain or flour
Contact dusts
178
What is the minimum gap that an adult mouse can gain entry through
9mm
179
What is the UKs legal requirement for live capture trap visits
Twice per 24 hours
180
The gassing of rodent burrows can only take place if the burrow is at least ... metres form buildings
3
181
Describe briefly 7 ways to combat bird pests
1) repellents
2) proofing
3) Netting
4) Trapping
5) Stupefying baits
6) Shooting
7) Mist netting
