- Production Batch Records8
- Critical Control Point Monitoring Log8
- Non-conformance and CAPA Register8
- Maintenance and Calibration Requests8
Made with care, made to standard
CAQA Orchard Lane Foods manufactures fruit based snacks, chilled juices and ambient sauces at its Dandenong South plant, bread and sweet bakery lines at its Shepparton bakery, and over the counter tablets and capsules for contract customers at its licensed pharmaceutical site in Western Sydney.
CAQA Orchard Lane Foods, food, beverage and pharmaceutical manufacturing
CAQA Orchard Lane Foods manufactures fruit based snacks, chilled juices and ambient sauces at its Dandenong South plant, bread and sweet bakery lines at its Shepparton bakery, and over the counter tablets and capsules for contract customers at its licensed pharmaceutical site in Western Sydney. The business supplies national supermarket private labels, food service distributors, pharmacy wholesalers and its own Orchard Lane retail range. Customers buy from Orchard Lane because every batch can be traced from raw material receipt to dispatch, every critical control point has a record, and the pharmaceutical site holds a current licence to manufacture under the Australian code of good manufacturing practice.
The business runs three sites and six departments. Dandenong South operates two production shifts from Monday to Saturday with a night hygiene crew, and houses the head office, the quality laboratory and the main warehouse. The Shepparton bakery runs a continuous three shift roster because bread does not wait, with a weekly maintenance window on Sunday. The Western Sydney pharmaceutical site works a single extended day shift inside controlled rooms with gowning, pressure cascades and environmental monitoring, and no product moves between the food and pharmaceutical sites. Each site has a site manager, a quality lead and a health and safety representative.
Safe by design
Food safety, product quality and people safety are built into the process, not inspected in at the end.
Right the first time
Every operator follows the batch record and the procedure so that rework, waste and recalls are the exception.
Say it, write it
If something is out of limit, we stop, we tell the supervisor and we record it. A deviation hidden is a recall waiting.
Respect for people
Shift workers, contractors and customers are treated with fairness and courtesy, and every voice on the floor is heard.
Services and operations
To make safe, consistent food, beverage and pharmaceutical products that meet every standard we are held to, every batch, every shift.
Fruit snack and sauce manufacturing
Cooking, depositing, drying and packing of fruit bars, fruit leathers and ambient sauces on two automated lines with metal detection and check weighing on every pack.
Chilled juice processing
Receival, washing, milling, pressing, pasteurising and cold filling of fruit juices with validated pasteuriser control and full cold chain records to dispatch.
High volume bread and sweet bakery
Continuous mixing, proving, baking, cooling and slicing of sandwich loaves, rolls and sweet buns for supermarket private label and food service customers.
Pharmaceutical contract manufacturing
Dispensing, granulation, compression, coating and encapsulation of over the counter tablets and capsules under the Australian code of good manufacturing practice.
Private label product development
New product trials, shelf life testing, nutrition information and label review for supermarket and pharmacy private label customers.
Warehousing and distribution
Ambient, chilled and quarantine storage, lot controlled picking and dispatch to distribution centres with temperature records for every chilled load.
Six departments, one workplace
Each department has a purpose, a lead, responsibilities, performance measures and the systems it works in. Students are placed in a department by their scenario.
Food and Beverage Production
Runs the fruit snack, sauce and chilled juice lines at Dandenong South across two shifts, following batch records and the food saf...
Visit departmentHigh Volume Bakery
Operates the Shepparton bread and sweet bakery lines on a continuous roster, scheduling production to customer orders, controlling...
Visit departmentPharmaceutical Manufacturing
Manufactures over the counter tablets and capsules for contract customers at the licensed Western Sydney site, working inside cont...
Visit departmentQuality and Food Safety
Owns the food safety program, the pharmaceutical quality system, the laboratory, supplier approval, complaints, recalls and intern...
Visit departmentWarehouse and Logistics
Receives, inspects and stores raw materials and packaging, holds quarantine stock until release, picks finished goods by lot and d...
Visit departmentMaintenance and Engineering
Keeps plant, utilities and packaging equipment at all three sites running safely and hygienically through preventive maintenance, ...
Visit departmentWorking systems with real records
Every system is live in your browser: create, update, search, move cards on a board and export what you did. Reset returns the seed data at any time.
Production Batch Records
Every food, beverage and pharmaceutical batch from planning to release, with line, quantity, status and the notes that support release.
8 recordsCritical Control Point Monitoring Log
Shift by shift monitoring records for every critical control point, with readings, limits, results and verification.
8 recordsNon-conformance and CAPA Register
Register of every non-conformance, deviation, complaint and safety incident with investigation, corrective and preventive action and closure status.
8 recordsMaintenance and Calibration Requests
Breakdown, preventive, calibration and hygienic design requests on plant and instruments at all three sites.
8 recordsRaw Material Receipts and Stock
Every inbound lot of raw material and packaging with supplier, quantity, allergen status and quarantine or release status.
8 recordsInbox
8 work requests from managers and colleagues, each linked to a scenario or a document.
Open inboxEight workplace scenarios
Sign in as a role, read the brief, work through the tasks using the documents and systems, then print an evidence summary for your assessor.
Run an allergen changeover on snack line 2
You are a Production Operator on snack line 2 at Dandenong South.
Open scenario Entry 2 hoursManage a metal detector test failure
You are a Packing Operator on snack line 2 at Dandenong South.
Open scenario Intermediate 3 hoursSchedule Thursday night bread production
You are the Assistant Bakery Supervisor at Shepparton.
Open scenario Advanced 4 to 5 hoursReview a batch record and investigate a hardness deviation
You are the Production Supervisor in the compression suite at Western Sydney.
Open scenario Intermediate 3 to 4 hoursOperate the compression suite under supervision
You are a trainee Pharmaceutical Production Operator at Western Sydney.
Open scenario Advanced 3 to 4 hoursConduct a mock recall of a raw material lot
You are the Quality Coordinator supporting the recall team at Dandenong South.
Open scenario Advanced 5 to 6 hoursConduct an internal audit of the juice line food safety program
You are the Internal Auditor in the Quality and Food Safety team.
Open scenario Entry 2 to 3 hoursReceive and inspect three inbound deliveries
You are a Receiving Storeperson at the Dandenong South warehouse.
Open scenarioNotice board All notices
- Quality Obsolete sleeve artwork found on snack line 2, check your packaging bays
9 September 2026 - Safety Heat resistant gauntlets now at every oven exit, Shepparton
7 September 2026 - Compliance Spring mock recall this month
8 September 2026
Coming up Calendar
- 14/09Monday toolbox talks, all lines
6:00 am, Each line muster point - 16/09Thursday night bread schedule due
12:00 pm, Bakery office, Shepparton - 18/09Allergen refresher training, day shift
9:00 am, Training room, Dandenong South - 21/09Internal audit opening meeting, juice line
9:00 am, Quality office, Dandenong South
Mapped to the Food, Beverage and Pharmaceutical
Every scenario lists the current units of competency and qualifications it supports, with assessor notes and a printable evidence summary. Use it with your own assessment tools or ask CAQA for a matched kit.