Vertical Form Fill Seal (VFFS) Machine Operator at Nutri Nuts and Fruits Limited

Role Purpose

• To set up, operate, monitor, clean and perform approved basic maintenance on the Vertical Form Fill Seal machine and its connected weighing, coding and inspection equipment. The operator is accountable for safe and efficient packing of roasted nuts at the correct weight, with secure seals, accurate coding, correct film and full batch traceability.

Key Responsibilities

Pre Start Inspection and Line Readiness

• Confirm the work order, product, batch, approved pack specification, target weight, correct packaging film, labels, coding details and required production quantity.
• Verify that the machine, product contact parts, conveyors, weighing system, metal detector, checkweigher, coder and surrounding area have been cleaned, inspected and released for use.
• Complete line clearance and remove previous product, film, labels, codes and documentation before introducing the next product or pack format.
• Inspect guards, interlocks, emergency stops, sensors, air supply, power supply, forming assembly, sealing jaws and other safety critical components before start up.
• Confirm that roasted nuts have been released, are correctly identified and are within approved holding conditions before feeding the packaging system.

Machine Set Up and Operation

• Install the correct forming collar or tube, film roll, sealing components and change parts for the approved pack format.
• Thread and align packaging film correctly, set film tension and registration, and configure bag length, fill weight, sealing temperature, sealing pressure, dwell time and cut position.
• Set up the product feed and weighing system, date or batch coder, gas flush where fitted, checkweigher, metal detector and automatic reject devices.
• Run controlled start up packs, make approved adjustments and obtain first off approval from Quality before routine production.
• Operate the line at the approved speed while maintaining stable product flow and preventing blockages, crushing, contamination or excessive product drop damage.

In Process Quality and Product Control

• Perform and record fill weight checks at the required frequency and adjust the approved set points to control underweight packs and excessive giveaway.
• Inspect seal position, seal strength, wrinkles, contamination in seals, cuts, pinholes, pack appearance and leak performance in accordance with the sampling plan.
• Verify product name, film, label, batch code, production date, expiry or best before date and print legibility throughout the run and after any stoppage or adjustment.
• Monitor metal detector, checkweigher and reject systems, complete challenge tests as assigned and account for all rejected packs.
• Identify unusual colour, odour, texture, breakage, seasoning distribution or evidence of under roasted or over roasted nuts and stop or escalate the issue promptly.

Changeover, Cleaning and Allergen Control

• Complete product, film and size changeovers in the approved sequence and within the expected changeover time without bypassing line clearance or quality approval.
• Dismantle only authorised machine components and clean food contact surfaces, hoppers, forming parts, conveyors and surrounding areas using approved methods and chemicals.
• Prevent allergen cross contact, mixing of products, mixing of packaging materials and contamination of clean components during cleaning and reassembly.
• Inspect components for damage, wear, trapped product or cleaning residue before reassembly and request verification where required.
• Dispose of product and packaging waste in designated containers and reconcile usable film, rejected packs and loose product at changeover and shift end.

Troubleshooting and Basic Maintenance

• Monitor the machine for abnormal temperature, vibration, noise, air leaks, film tracking problems, seal defects, sensor faults, feeding errors and recurring alarms.
• Clear minor jams and perform approved adjustments, cleaning, lubrication and component replacement within the operator's training and authority.
• Stop and isolate the machine before clearing jams, cleaning or accessing hazardous parts, and never bypass guards, interlocks or sensors.
• Record downtime accurately, report defects promptly and provide clear fault information to the Production Supervisor and Maintenance team.
• Support planned preventive maintenance and verify that the machine is clean, guarded and safe before production resumes.

Documentation, Safety and Teamwork

• Complete production, quality, downtime, cleaning, changeover, film reconciliation, rejection and handover records accurately and in real time.
• Maintain full product and packaging traceability and protect the identification and status of released, held, rejected and rework materials.
• Follow Good Manufacturing Practices, personal hygiene, food safety, allergen, chemical, foreign material and pest prevention requirements.
• Maintain a clean, dry and orderly work area and immediately report spills, unsafe conditions, injuries, near misses or contamination risks.
• Communicate effectively with the Roaster Operator, Quality team, Packing Assistants, Maintenance team and incoming shift to maintain smooth product flow.

Decision Authority and Escalation

• Stop the VFFS line where there is an unsafe condition, wrong material, coding error, weight failure, seal defect, inspection failure, contamination risk or loss of traceability.
• Make routine parameter adjustments within approved operating ranges and request first off approval after significant changes.
• Place suspect packs in the designated hold area pending supervisor or Quality assessment, while preserving batch identification.
• Escalate repeated alarms, equipment damage, uncontrolled film or product loss, metal detector failure, serious defect or inability to meet specification immediately.

Minimum Qualifications and Experience

Education and Training

• Craft certificate, technical certificate or diploma in Food Processing, Mechanical Engineering, Electrical Engineering, Mechatronics, Plant Operations or a related discipline.
• Training in VFFS operation, Good Manufacturing Practices, HACCP awareness, food allergen control and machine safety is preferred.

Experience

• At least two years of hands on experience operating and setting up a Vertical Form Fill Seal machine in food manufacturing.
• Hands on experience in nut roasting and processing is mandatory, with the ability to identify common roasted nut quality defects.
• Experience with weighers, date or batch coders, metal detectors, checkweighers, gas flushing systems and automated reject devices is strongly preferred.

Knowledge, Skills and Competencies

• Practical understanding of film threading, registration, forming, filling, sealing, coding and inspection controls.
• Mechanical awareness, disciplined troubleshooting and ability to recognise when a fault requires Maintenance support.
• Strong attention to weight, seals, codes, traceability and detail, with accurate numerical and record keeping skills.
• Ability to follow specifications and standard operating procedures consistently, even when production pressure is high.
• Safety awareness, personal accountability, teamwork and clear shift handover communication.