1. Role Overview The Plant Manager is the single-point owner of the entire plastic pyrolysis plant — accountable for safe, continuous, cost-efficient conversion of mixed plastic waste into pyrolysis oil, carbon black and non-condensable gas. The role combines hands-on process engineering with full P&L;, EHS and team-management responsibility. The incumbent will drive uptime, yield, quality and compliance while building the operational culture of a growing circular-economy enterprise. 2.

Key Responsibilities
A. Plant Operations & Production
• Own the end-to-end pyrolysis process: feedstock preparation, shredding, reactor charging, controlled heating cycle, condensation train, oil collection, char discharge and gas handling / flare / power generation.
• Drive key operating KPIs — reactor availability (target ≥ 85%), oil yield (target ≥ 55% on dry feed basis for mixed PE/PP/PS, ≥ 40% for mixed MSW plastic), carbon black and non-condensable gas yields, batch cycle time, specific energy consumption (kWh/MT feed).
• Monitor and optimise reactor temperature profile (typical 350–450 °C), residence time, catalyst loading (if used), condenser temperatures and vacuum/pressure control.
• Oversee daily, weekly and monthly production planning, feedstock scheduling and batch sheet closure. B. Safety, Health & Workplace (SHE)
• Enforce zero-tolerance safety culture — pyrolysis is a high-hazard operation (flammable vapours, high temperature, hydrocarbon gas inventory). Target: zero LTI.
• Implement and audit HAZOP, Permit-to-Work (PTW), LOTO, hot-work, confined-space and emergency response procedures.
• Ensure full compliance with CPCB / SPCB norms (air emissions, water discharge, hazardous waste handling under HWM Rules 2016), Factory Act 1948, PESO (if LPG/diesel storage > threshold), and Fire NOC.
• Lead monthly mock drills, SHE committee meetings, incident investigation and CAPA closure. C. Quality & Product
• Ensure pyrolysis oil meets agreed buyer specifications — density, calorific value (typical 38–42 MJ/kg target), flash point, water content, sulphur, viscosity, solids content.
• Oversee in-house QC lab or external testing arrangements; sign off every tanker COA before dispatch.
• Drive upgrading initiatives — distillation, de-chlorination, de-sulphurisation if required by customer specs or regulatory norms. D. Feedstock, Supply Chain & Costs
• Secure daily feedstock requirement in coordination with Procurement; vet aggregators and MRFs on quality,



moisture, chlorine (PVC) content and heavy metals.
• Own the plant P&L; — monthly budget vs. actual on feedstock cost, utilities, consumables, labour, maintenance, logistics.
• Drive cost-per-MT-feed and cost-per-litre-oil improvement; identify yield and energy recovery projects. E. Maintenance & Reliability
• Lead preventive maintenance program for reactor shell, agitator seals, condensers, pumps, blowers, scrubbers, DG sets and material-handling equipment.
• Plan annual turnaround / shutdown — reactor coke removal, refractory inspection, pipe-flange integrity, PRV testing.
• Maintain MRO inventory within budgeted norms and critical-spares list. F. Team Leadership & Culture
• Lead a team of 10-20 people across operations, maintenance, QC, logistics and admin (depending on plant size and shift pattern).
• Build shift supervisor capability, drive on-the-job training and SOP adherence, run daily shift handover meetings. G. Regulatory, Reporting & Stakeholder Management
• Interface with CPCB/SPCB, Factory Inspector, Pollution Control Board auditors, EPR authorities and local administration.
• Submit timely monthly/quarterly compliance returns, EPR reporting under Plastic Waste Management Rules. & ISCC data
• Report weekly operations dashboard to Director/CEO (production, safety, quality, costs, HR, deviations). 3. Required Qualifications & Experience
• B.
E. / B.
Tech in Chemical Engineering, Mechanical Engineering, Petroleum Engineering or Polymer Engineering from a recognised institute. M.
Tech or MBA (Operations) a plus.
• 3–10 years' total experience in process plant operations, with minimum 2 years in a Plant Manager / Deputy Plant Manager role.
• Direct hands-on experience in pyrolysis, waste-to-energy, refinery/distillation, bitumen, carbon black, rubber recycling, biomass gasification, or similar thermal process plant preferred.
• Demonstrated P&L; accountability for a plant of ≥ 20 MT/day throughput or equivalent.
• Thorough working knowledge of HAZOP, PSSR, MOC, and IS/OSHA safety frameworks.
• Working knowledge of CPCB,



PCB, PWM Rules 2016 (and amendments), EPR regulations, and ISO 9001/14001/45001 & ISCC implementation.
• Experience managing unionised or semi-skilled workforce in a plant environment.
• Computer-literate —ERP (production module), MS Excel modelling, basic DCS/SCADA familiarity. 4. Preferred / Nice-to-Have
• Prior exposure to continuous or semi-continuous pyrolysis reactor designs (rotary kiln, auger, fluidised bed).
• Experience in product quality upgradation (fractional distillation, hydrotreatment, catalytic cracking) for pyrolysis-derived oil.
• Experience selling or qualifying pyrolysis oil to industrial end-users (cement kilns, steel re-rolling mills, boilers, co-processing).
• Exposure to Carbon Credit / Plastic Credit / EPR trading mechanisms.
• Published or filed patents / papers in plastic pyrolysis or waste-to-energy space. 5. Core Competencies
• Hands-on, floor-walking leadership style — minimum 60% time on the shop floor expected.
• First-principles process engineering thinking — ability to diagnose yield drops, deviations and reactor upsets without external support.
• Strong commercial instinct — understands that every rupee saved per MT feedstock or per litre of oil flows to the P&L.;
• Cool-headed in crisis — can run an emergency shutdown or incident response without escalation.
• Clear, concise written and verbal communication; confident with regulators and buyers alike.
• Builder's mentality — comfortable working in an entrepreneurial, resource-constrained early-growth environment. 6. Success Metrics (First 12 Months)
• Reactor availability raised to ≥ 85% from baseline.
• Pyrolysis oil yield improved by at least 3 percentage points vs. baseline.
• Zero reportable safety incidents (LTI = 0, fire incidents = 0).
• 100% CPCB/SPCB compliance — no show-cause notices, no closure notices.
• Plant conversion cost (₹ per MT feed) reduced by ≥ 8% vs. baseline.
• Shift-supervisor team upskilled: 100% certified on SOPs; one supervisor identified as successor-track.
• Reporting

location:
VASAI , Mumbai
• Working pattern: general shift with on-call responsibility; plant runs 24×7 on 3-shift pattern. 7.

How to Apply
Interested candidates may share their updated CV, current CTC and notice period with Bioplastica Energy Pvt. Ltd.( Group company of Emco Dyestuff Pvt Ltd ) via the contact point

📌 Plant Manager (Mumbai)
🏢 Emco Dyestuff
📍 Mumbai