Control Room Operator Process at Kilombero Sugar

Location: Morogoro, Tanzania
Job Type: Full Time
Employment Type: Technical/Skilled
Workplace Type: Onsite

Job Role:

The successful candidate will be responsible to operate and monitor process units including Mixed Juice handling, Juice heating (screened and clarified juice heating), Clarification, Filtration and Evaporation. Ensuring set target parameters for each unit is achieved as per shift KPI. Back-end maintenance during breakdown and off crop.

Responsibilities:

• Monitors the performance of plant units (juice heating, clarification, filtration, evaporation) on a continual shift basis using the DCS system to achieve target parameters as per KPI
• Monitors key parameters such as juice temperature, clear juice pH, syrup brix, pol% filter cake, pressure, and vacuum settings in real time and takes appropriate corrective actions to meet Food Safety Quality standards and specifications
• Adjusts process variables in conjunction with the Raw House Foreman to ensure plant units operate as per procedure and KPI targets
• Solves process problems and deviations using corrective actions to meet production KPIs
• Monitors plant profiles using online and laboratory analysis results and takes corrective actions to maintain product quality and minimize losses
• Captures required data on computer to calculate plant efficiencies
• Diagnoses breakdown causes with Raw House Foreman and operators using tools such as 5 Why and Fishbone analysis
• Responsible for shutdown and startup of plant units as per SOPs
• Operates mixed juice heating station to achieve correct flashing temperature before clarification
• Regulates clarification station ensuring proper lime and flocculant dosing for good clear juice quality
• Ensures safe handling of clarifier during long stops following safety procedures
• Maintains steady flow across juice heaters and evaporators and ensures proper level control to avoid losses
• Monitors vapor bleed distribution for steam economy and ensures efficient steam recovery
• Adheres to safety procedures and maintains control room housekeeping, quality, and environmental standards
• Records production data and shift information in logbooks and systems
• Trains plant personnel on control room operations when required
• Acts as safety watch during shutdowns to ensure compliance with safety standards
• Ensures syrup production with brix of 63–69% while minimizing sucrose inversion and colour formation
• Ensures evaporator isolation and lockout procedures during cleaning as per SOPs
• Participates in improvement meetings and acts as SME for assigned plant units
• Inspects plant equipment and reports abnormalities such as leaks or vacuum issues
• Ensures condensate quality and reports deviations
• Assists maintenance teams during scheduled stops
• Supports lime and flocculant preparation as per SOPs when required
• Monitors mud belt filters and ensures correct operating parameters
• Ensures proper shift handover procedures are followed
• Reports any incidents affecting safety or environment before end of shift
• Performs any other duties assigned by supervisor
• Supervises and delegates tasks to site operators/attendants for optimal operation

Must Have Skills:

• Operation procedures of evaporators
• Plant machinery maintenance and repair
• Safety and lockout procedures
• Equipment operations
• Troubleshooting skills
• Communication skills
• Numeracy skills
• Computer literacy

Qualifications:

• Form 6 or A-Level Secondary Education with Mathematics and Science
• Diploma in Sugar Production
• Diploma in Chemical/Mechanical Engineering/Production Management
• At least 3 years’ experience in sugar industry
• Experience in factory production environment, preferably sugar factory