Job Description

General Manager Operations (Polymer Technology, Mixing & Polymer Recycling)

Position: General Manager – Operations

Location: Gummidipoondi, Chennai, Tamil Nadu

Industry: Plastic Recycling / Polymer Compounding / Circular Economy

Department: Operations

Reporting To: Managing Director

Experience: 15-25 Years

Qualification:

- B.E./B.Tech in Polymer Technology / Plastic Technology / Chemical Engineering
- M.Tech in Polymer Technology (Preferred)
- MBA (Operations) is an added advantage

Role Purpose

The General Manager – Operations will be responsible for leading the complete manufacturing operations of a polymer recycling and compounding facility. The role requires deep expertise in polymer technology, formulation development, mixing, compounding, extrusion, and recycled polymer processing while driving operational excellence, productivity, quality, cost optimization, and customer satisfaction.

The incumbent will oversee end-to-end plant operations, including production, maintenance, quality, planning, engineering, EHS, technical development, and continuous improvement initiatives.

Key Responsibilities

Plant Operations

- Lead complete plant operations to achieve production, quality, safety, and profitability targets.
- Drive operational excellence across recycling, compounding, extrusion, pelletizing, and packaging processes.
- Ensure optimum utilization of manpower, machinery, and raw materials.
- Develop and implement operational strategies to improve efficiency and plant performance.
- Monitor production KPIs and implement corrective actions.

Polymer Technology & Product Development

- Lead formulation development for recycled polymer compounds.
- Develop customized grades based on customer specifications.
- Optimize recipes for cost, processability, and performance.
- Improve polymer properties including:
- Melt Flow Index (MFI)
- Tensile Strength
- Flexural Strength
- Impact Strength
- Density
- Thermal Stability
- Colour Consistency

- Lead trials for recent products and commercial production.

Polymer Mixing & Compounding

- Manage polymer mixing, blending, compounding, and extrusion operations.
- Optimize mixing cycles and extrusion parameters.
- Improve dispersion of fillers, additives, and pigments.




- Reduce material degradation during processing.
- Enhance product consistency across batches.

Polymer Recycling

- Lead recycling operations involving post-industrial (PIR) and post-consumer (PCR) plastics.
- Improve recovery and utilization of recycled materials.
- Develop high-performance recycled compounds.
- Minimize contamination and maximize material recovery.
- Support sustainability and circular economy initiatives.

Production Planning & Manufacturing Excellence

- Ensure achievement of daily, weekly, and monthly production targets.
- Improve Overall Equipment Effectiveness (OEE).
- Reduce downtime and improve plant utilization.
- Drive Lean Manufacturing, TPM, Six Sigma, Kaizen, and 5S initiatives.
- Improve productivity through automation and process optimization.

Quality Management

- Ensure compliance with customer specifications and quality standards.
- Review laboratory reports and product performance.
- Reduce customer complaints and internal rejection.
- Lead root cause analysis and corrective actions.

Maintenance & Engineering

- Oversee preventive, predictive, and breakdown maintenance.
- Improve equipment reliability and availability.
- Support installation and commissioning of new machinery.
- Drive energy conservation and utility optimization.

Commercial & Cost Control

- Optimize formulation costs without compromising quality.
- Improve raw material yield and reduce wastage.
- Control operational expenditure.
- Support procurement in evaluating new suppliers and materials.

'Customer & Technical Support

- Participate in customer technical meetings.
- Resolve processing and product-related issues.
- Support Business Development with technical presentations.
- Lead product validation and approvals.

People Leadership

- Lead Production, Maintenance, Quality, Planning, Warehouse, Engineering, and Technical teams.




- Build a high-performance culture through coaching and mentoring.
- Develop succession plans and technical capability within the organization.

Safety, Environment & Compliance

- Ensure compliance with statutory, environmental, and safety regulations.
- Promote a strong EHS culture.
- Drive sustainability initiatives aligned with circular economy objectives.

Technical Expertise

Polymer Processing

- Polymer Compounding
- Polymer Mixing
- Polymer Formulation Development
- Twin Screw Extrusion
- Single Screw Extrusion
- Pelletizing
- Polymer Blending
- Additive Selection
- Colour Matching
- Process Optimization

Polymer Recycling

- Mechanical Recycling
- Post-Consumer Recycling (PCR)
- Post-Industrial Recycling (PIR)
- Plastic Waste Segregation
- Washing & Drying Processes
- Melt Filtration
- Decontamination
- Circular Economy Practices

Polymer Knowledge

Experience with one or more of:

- Polypropylene (PP)
- PPCP
- PPHP
- HDPE
- LDPE
- LLDPE
- ABS
- HIPS
- GPPS
- Nylon (PA)
- Polycarbonate (PC)
- PC/ABS
- PET
- PVC
- Engineering Plastics

Equipment Exposure

- Twin Screw Compounders
- Single Screw Extruders
- High-Speed Mixers
- Agglomerators
- Shredders
- Granulators
- Pulverizers
- Pelletizers
- Material Dryers
- Gravimetric Feeders
- Injection Moulding Machines (Preferred)

Leadership Competencies

- Strategic Operations Management
- Manufacturing Excellence
- Operational Planning
- Team Leadership & People Development
- Continuous Improvement
- Cost Optimization
- Customer Focus
- Data-Driven Decision Making
- Strong Technical & Commercial Acumen

Preferred Industry Experience

- Plastic Recycling
- Polymer Compounding
- Engineering Plastics
- Automotive Polymer Components
- Plastic Processing
- Circular Economy
- Sustainable Materials Manufacturing

Key Performance Indicators (KPIs)

- Production target achievement
- Overall Equipment Effectiveness (OEE)
- Reduction in manufacturing cost per kg
- Yield improvement and scrap reduction
- New recycled polymer grade development
- Customer complaint reduction
- On-time delivery performance
- Energy consumption optimization
- Plant profitability (EBITDA)
- Safety performance (Zero Lost Time Incidents)
- Employee productivity and retention

📌 GM Operations - Polymer Technologist - Gumudipoondy - Redhills (Chennai)
🏢 SAI Hr Consultants
📍 Chennai