Engineering Head - Aseptic Technology & Maintenance

Role Purpose :

To assist the complete Engineering, Operation-readiness, Maintenance, and Technical compliance of the aseptic manufacturing setup - covering PET blow moulding, aseptic filling, packing lines, utilities, qualification documentation, and EHS, leading to stable and compliant commercial production.

Key Responsibilities :

Aseptic Manufacturing Equipment

Technical Ownership :

End-to-end technical responsibility for :

- PET blow moulding operations (preform handling, heating, stretch blow moulding, bottle quality control).

- Aseptic bottle sterilization systems (HO).

- Aseptic filling & capping machines.

- Secondary packing lines (inspection, labelling, collation, shrink wrapping, palletization).

Deep involvement in :

- Machine setup and parameter optimization.

- Sterilization process understanding and control.

- Line balancing and efficiency improvement.

- Equipment capability and reliability assessment.

- Ensure machines are not only installed, but capable of consistent aseptic commercial operation.

Running, Control & Maintenance of Equipment :

Overall responsibility for :

- Preventive and breakdown maintenance of all manufacturing equipment.

- Spares planning and critical part management.

- Root cause analysis for repeated failures or stoppages.

- Improving OEE and reducing unplanned downtime.

Ensure maintenance practices which are:

- GMP-compliant.

- Well-documented.

- Aligned with aseptic risk management.

Utilities - Aseptic Critical Systems Ownership :

Full technical ownership of all utilities required for aseptic filling in PET bottles, including :

- RO / PW / clean water systems.

- Clean steam and process steam.

- Sterile compressed air.

- HVAC systems with HEPA filtration and pressure cascades.

- CIP / SIP systems.

- Chilled water, cooling towers, electrical power systems.

Ensure utilities are :

- Properly designed, sized, commissioned, and maintained.

- Integrated with production and automation systems.

- Reliable, redundant, and audit-ready.

Qualification, Validation & Documentation :

Own engineering-side execution and documentation for :

- DQ, IQ, OQ, PQ of all equipment and utilities.

- FAT and SAT activities.

- Equipment manuals, SOPs, calibration and maintenance records.

Ensure readiness of documentation for :

- Commercial manufacturing.

- Internal and regulatory audits.

- Ongoing lifecycle compliance.

- Work closely with QA to ensure engineering compliance supports GMP and aseptic requirements.

Training & Capability Building :

Plan and execute structured training programs for :

- Engineering team.

- Operators and technicians.

- Maintenance personnel.

Ensure teams are trained on:

- Equipment operation.

- Sterilization principles.

- Aseptic risk awareness.

- Troubleshooting and maintenance best practices.

- Build long-term in-house technical capability, not OEM dependence.

EHS (Environment, Health & Safety) :

Ensure all engineering activities comply with EHS norms, including :

- Equipment safety.

- Chemical handling (HO, CIP chemicals).

- Pressure systems and utilities safety.

- Electrical and mechanical safety.

Drive safe engineering practices during :

- Installation.

- Commissioning.

- Routine operations and maintenance.

Candidate Profile :

Mandatory Technical Experience :

Strong, hands-on experience in :

- PET blow moulding operations.

- Aseptic filling processes.

- Packing lines.

- Utilities supporting aseptic manufacturing (PET).

Deep understanding of :

- Sterilization methods and controls.

- Engineering aspects of aseptic manufacturing equipment.

- Machine operation, maintenance, and troubleshooting.

- Validation and documentation requirements for commercial manufacturing.

Educational Background :

- B.Tech / M.Tech.

- Experience in beverage, dairy or nutrition.