As a Packing Plant CCR Operator, you will be responsible for the operation and monitoring of the rotary packers, conveyors, and dispatch systems via the Central Control Room (CCR). You will ensure optimal utilization of all packing lines, manage silo levels, and coordinate dispatch activities while maintaining high standards of quality and safety. Your role involves supervising floor staff and coordinating with maintenance and QA teams to ensure seamless production and delivery of cement products.
Key Responsibilities
Rotary Packer Operation & Control
- Operate and monitor rotary packers (Ventomatic or Haver & Boecker equivalent), conveyors, air slides, bag applicators, and reject systems via the CCR.
- Maintain target packing rates (tph) and ensure optimal utilization of all packing lines throughout the shift.
- Monitor and control bag weight accuracy within specified tolerances, initiating corrective adjustments as required.
- Respond to packer alarms, bag rejection spikes, and line stoppages promptly, coordinating with field operators to restore normal operation.
- Coordinate packer start-up and shutdown sequences in line with standard operating procedures.
Bulk & Bag Dispatch Coordination
- Coordinate bulk and bagged cement dispatch activities in alignment with daily sales orders and dispatch schedules.
- Liaise with the dispatch team to confirm truck loading sequences, product allocations, and loading bay assignments.
- Monitor truck turnaround times (TAT) within the packing and dispatch area and flag delays or bottlenecks to the Shift Coordinator.
- Ensure dispatch documentation including loading sheets, weighbridge tickets, and delivery notes are verified and accurate prior to truck departure.
- Communicate dispatch status updates to the supply chain and customer service teams in a timely manner.
Silo Level Monitoring & Product Changeover Management
- Monitor cement silo levels continuously and coordinate feed and extraction sequences in line with production and dispatch requirements.
- Execute product changeover activities between cement grades following defined SOPs to eliminate cross-contamination.
- Coordinate silo switching decisions with the Shift Coordinator and supply chain team to align with dispatch priorities.
- Maintain accurate silo allocation and grade identification records throughout the shift.
- Escalate low silo levels or supply disruptions to the Shift Coordinator promptly to prevent dispatch interruptions.
Compressed Air & Pneumatic Conveying System Management
- Monitor compressor performance, compressed air system pressure, and air slide operation to ensure uninterrupted cement conveying to packing lines.
- Identify and report compressed air leaks, pressure drops, or conveying system blockages and coordinate corrective actions with maintenance.
- Optimize compressed air usage and compressor loading to minimize specific energy consumption within the packing plant.
- Monitor dust extraction and filter systems to ensure effective dust suppression and compliance with emission standards.
Packing Plant Manpower Supervision
- Supervise packing plant operators, bag attendants, palletisers, and cleaners assigned to the shift, ensuring effective task allocation based on operational priorities.
- Enforce discipline, accountability, and performance standards throughout the shift.
- Conduct routine field inspection rounds to verify compliance with operational procedures and equipment status.
- Mentor junior operators and promote skill development, process awareness, and safety culture within the team.
- Coordinate handover briefings at shift changeover to ensure complete and accurate status communication to the incoming team.
Quality Assurance & Dispatch Accuracy
- Ensure the correct cement grade is packed and dispatched in accordance with customer order specifications at all times.
- Coordinate with the QA/QC laboratory for product quality verification and prompt feedback on any out-of-specification results.
- Monitor bag weight statistics and reject rates, escalating trends that indicate packer calibration or feed issues.
- Enforce grade segregation and product identification protocols throughout packing and loading operations.
- Escalate quality non-conformances or dispatch errors to the Shift Coordinator immediately.
Documentation & Shift Reporting
- Maintain accurate and up-to-date shift logs covering packing volumes, downtime events, equipment status, and process deviations.
- Prepare and submit comprehensive shift production and dispatch reports to the Shift Coordinator at the end of each shift.
- Complete shift handover documentation thoroughly, ensuring the incoming CCR Operator is fully briefed on plant status, outstanding issues, and pending actions.
- Update production and dispatch data in plant reporting and ERP systems accurately and on time.
Health, Safety & Environmental Compliance
- Ensure all packing plant and dispatch operations are conducted in full compliance with Savannah Cement HSE policies and statutory requirements.
- Enforce Lock-Out/Tag-Out (LOTO) procedures during all maintenance interventions on controlled packing plant equipment.
- Lead shift safety briefings, toolbox talks, and pre-task risk assessments for the packing plant team.
- Monitor dust extraction systems and prevent unsafe dust accumulation in packing and dispatch areas.
- Stop unsafe operations immediately and escalate to the Shift Coordinator without delay.
- Report all incidents, near-misses, and HSE non-compliances promptly and support investigation processes as required.
- Promote strong housekeeping standards and a culture of safety awareness within the packing and dispatch areas.
Maintenance Coordination & Equipment Reliability
- Liaise with the maintenance team to communicate equipment defects, packer faults, and repair requirements identified during the shift.
- Follow up on outstanding maintenance work orders that affect packing line availability or throughput performance.
- Support planned maintenance shutdown preparations by coordinating equipment isolation and safe handover from the CCR.
- Escalate recurring equipment failures and reliability concerns to the Shift Coordinator for engineering review.
Academic and Professional Qualifications
- Bachelor's degree or Diploma in Chemical Engineering, Process Engineering, Mechanical Engineering, Electrical Engineering, or Mechatronics Engineering.
- Minimum of 5 years of hands-on experience in cement packing plant operations, with demonstrated CCR or supervisory responsibility.
- Hands-on experience operating rotary packer systems (Ventomatic, Haver & Boecker, or equivalent) is required.
- Proficiency in operating DCS/SCADA control systems; ability to navigate process schematics, alarm panels, and trend data.
- Strong understanding of pneumatic conveying systems, compressed air management, and dust extraction operations.
- Experience with bulk loading systems and weighbridge-integrated dispatch operations is an added advantage.
- Supervisory experience in a shift-based manufacturing environment is an added advantage.
- Familiarity with SAP Plant Maintenance or equivalent ERP/CMMS for downtime and production reporting is advantageous.
