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 & Environment (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.
- Transparent, 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 - Plastic Pyrolysis (Mumbai)
🏢 Emco Dyestuff
📍 Mumbai