Roles and responsibilities:

1. Production Planning & Target Achievement

- Execute daily production plan for Grinding and Calcination as per production requirement.
- Ensure achievement of daily, shift-wise and monthly production targets.
- Plan raw gypsum feeding, grinding and calcination according to silo levels and downstream requirements.
- Coordinate with Dispatch, Packing and other production sections to maintain continuous plant operation.

2. Grinding Section

Responsible for operation and monitoring of:

- Crusher
- 4-Roller Mill / 6-Roller Mill
- Screw Conveyors
- Bucket Elevators
- Rotary Valves
- Feeding Systems
- Blowers
- Dust Collection Systems
- Gypsum Storage Silos

Key responsibilities

- Maintain required mill feed rate and grinding capacity.
- Monitor gypsum feed size and ensure proper grinding.
- Maintain required product fineness.
- Monitor mill vibration, differential pressure, motor load and other operating parameters.
- Ensure stable feeding to the calcination section.
- Avoid mill choking, overloading and empty running.
- Optimize mill operation to reduce specific power consumption.
- Coordinate with Maintenance for abnormalities and breakdowns.

3. Calcination Section

Responsible for operation and monitoring of:

- Vertical Calciner / Kettle
- Boiler / TFH
- Coal Feeding System
- ID Fan / Blower
- Rotary Valves
- Screw Conveyors
- Calcined Gypsum Silos
- Associated temperature, pressure and instrumentation systems

Key responsibilities

- Maintain required calcination temperature and residence time.
- Ensure reliable and continuous feeding of gypsum to the calciner.
- Monitor:

o Feed rate o Calcination temperature o Material temperature o Coal consumption o Airflow o Draft/pressure o Boiler/TFH parameters o Product quality




- Ensure proper calcination and avoid under-calcination or over-calcination.
- Maintain required coal consumption per MT of stucco.
- Optimize fuel and air ratio for efficient operation.
- Monitor calcined gypsum quality and take corrective action whenever parameters deviate.

4. Process Control & Optimization

- Maintain process parameters within the defined operating range.
- Identify abnormal trends before they result in production loss or quality problems.
- Optimize mill capacity, calcination rate and fuel consumption.
- Monitor specific power consumption and coal consumption per MT.
- Identify opportunities for energy and process optimization.
- Maintain operating standards and SOPs.

5. Quality Control

- Ensure required gypsum/stucco quality as per specification.
- Coordinate with the Quality/Lab team for:

o Fineness o Setting time o Free moisture o Combined water o Bulk density o Other applicable quality parameters
- Take immediate corrective action in case of quality deviation.
- Maintain traceability between raw material, process parameters and finished product.

6. Equipment & Process Reliability

- Carry out routine inspection of operating equipment.
- Identify abnormal sound, vibration, temperature, leakage, belt/chain condition, etc.
- Immediately inform Maintenance about equipment abnormalities.
- Coordinate with Maintenance during breakdowns and planned maintenance.




- Ensure equipment is handed over safely for maintenance and properly taken back after completion.
- Minimize production loss due to operational issues.

7. Coal Consumption Monitoring

- Monitor daily coal consumption and calculate kg coal/MT of stucco.
- Reconcile coal feeding with production.
- Identify abnormal/excessive coal consumption.
- Maintain daily coal consumption records.
- Work on initiatives for coal reduction and heat recovery.
- Support implementation of coal weighment and automated feeding systems.

8. Silo & Material Management

- Maintain optimum levels of:

o Raw gypsum silo o Ground gypsum silo o Calcined gypsum/stucco silo
- Avoid silo overflow and low-level situations.
- Coordinate grinding and calcination operation based on silo availability.
- Ensure proper material transfer and avoid unnecessary material handling losses.

9. Shift Management

- Supervise operators and helpers working in Grinding and Calcination.
- Allocate manpower effectively.
- Ensure proper shift handover.
- Maintain shift production and process reports.
- Ensure operators follow SOPs, checklists and operating instructions.
- Monitor operator discipline and performance.

10. Safety

- Ensure safe operation of Grinding and Calcination equipment.
- Ensure PPE compliance.
- Follow LOTO requirements during maintenance.
- Ensure safe handling of hot material, coal and rotating equipment.
- Report unsafe conditions immediately.
- Ensure compliance with plant safety procedures and emergency protocols.

Preferred Candidate:

Education - Diploma/ BE (Mechanical)

Experience - 4-6 years of relevant experience

Product knowledge- Gypsum / Cement

Behavioural Competencies - Ownership & Accountability, Learning Agility, Problem Solving &

Kindly share your resume at [email protected]

📌 Executive- Operations(Production) (Ankleshwar)
🏢 Walplast Products
📍 Ankleshwar