1. Job Purpose

To independently operate, monitor and control food extrusion machinery used in the manufacturing of breakfast cereals and other extruded food products.

The operator will be responsible for achieving production targets while maintaining product quality, process consistency, machine efficiency, food safety, workplace safety and minimum production wastage.

The candidate must have practical experience in operating extruder machines, preferably twin-screw food extruders used for breakfast cereal manufacturing.

2. Key Roles and Responsibilities

A. Extruder Machine Operation

- Operate and monitor food extrusion machines as per approved production plans and standard operating procedures.
- Independently handle machine start-up, operation, changeover and shutdown activities.
- Understand and control the following critical machine parameters:
- Barrel temperature and zone-wise temperature settings.
- Screw speed (RPM).
- Feeder speed and raw material feeding rate.
- Motor load and operating pressure.
- Moisture content of the premix.
- Water and steam flow, wherever applicable.
- Die pressure and product discharge consistency.
- Ensure continuous and uniform feeding of raw materials into the extruder.
- Maintain consistent product shape, size, texture, density and expansion.
- Monitor extruder output and ensure production as per the defined hourly capacity.
- Identify process abnormalities and take corrective action within approved operating limits.

B. Process Control and Product Quality

- Ensure products are manufactured according to approved product specifications.
- Monitor product characteristics such as:
- Product appearance and colour.
- Shape and dimensions.
- Expansion ratio.
- Texture and crispiness.
- Moisture content.
- Bulk density and product consistency.
- Coordinate with the Quality Assurance team for in-process inspection and sample approval.
- Immediately report deviations in product quality, process parameters or machine performance.
- Prevent cross-contamination and product mix-ups during product changeovers.
- Maintain batch traceability and ensure correct RM and premix usage.
- Ensure rejected and off-specification materials are properly segregated and identified.

C. Machine Maintenance and Troubleshooting

- Conduct routine machine inspections before starting production.
- Identify abnormalities such as unusual noise, vibration, overheating, pressure fluctuations and motor overload.
- Monitor the condition of screws, barrels, dies, cutters,



feeders and other critical components.
- Coordinate with the Maintenance Department for preventive and breakdown maintenance.
- Ensure proper cleaning and assembly of machine components after maintenance.
- Maintain machine cleanliness and operating conditions.
- Report recurring breakdowns and recommend improvements to improve machine reliability.
- Never undertake unauthorized mechanical or electrical repairs.

D. Production Planning and Output Achievement

- Execute production according to the daily production schedule.
- Achieve the planned hourly and shift-wise production targets.
- Monitor machine output, downtime and production losses.
- Minimize material wastage during start-up, shutdown and product changeovers.
- Coordinate with premix preparation, dryer, seasoning and packing teams wherever applicable.
- Ensure smooth material flow and avoid unnecessary production interruptions.
- Support production trials and current product development activities.

E. Food Safety, Hygiene and GMP

- Follow GMP, GHP and food safety requirements at all times.
- Ensure the extruder machine and surrounding area are cleaned as per the approved cleaning schedule.
- Follow personal hygiene requirements, including proper PPE and protective clothing.
- Prevent foreign-body contamination during processing.
- Follow allergen control and product changeover cleaning procedures.
- Maintain proper housekeeping under 5S principles.
- Follow food safety instructions and report any contamination risks immediately.

F. Documentation and Reporting

- Maintain daily production records and machine operation logs.
- Record critical process parameters at defined intervals.
- Maintain records of production quantity, rejection, wastage and downtime.
- Document machine breakdowns and corrective actions.
- Record shift handover details and pending maintenance issues.
- Ensure all production documentation is accurate and updated in a timely manner.

3. Technical Knowledge Required

The candidate should have practical knowledge of:

- Single-screw and preferably twin-screw food extrusion technology.




- Extruder machine operation and process control.
- Screw configuration and die operation.
- Temperature and moisture management.
- Raw material feeding and premix preparation.
- Product expansion and texture control.
- Extrusion troubleshooting and process optimization.
- Dryer coordination and downstream processing.
- Preventive maintenance and basic machine inspection.

Preferred exposure: Corn flakes, rice-based cereals, multigrain cereals, choco balls, fruit rings, cereal snacks and other expanded breakfast cereal products.

4. Educational Qualification

- ITI / Diploma in Mechanical, Electrical, Production or Food Technology preferred.
- Candidates with strong practical extrusion machine operating experience may also be considered.

5. Experience Requirements

- Minimum 5 years of hands-on experience in operating food extrusion machinery.
- Experience in breakfast cereal or food extrusion manufacturing preferred.
- Experience in handling production targets and machine troubleshooting.
- Ability to independently manage machine operation during the assigned shift.
- Experience in handling twin-screw extruders will be an added advantage.

6. Key Performance Indicators (KPIs)

The operator's performance will be evaluated based on:

- Production target achievement (%).
- Hourly machine output (kg/hour).
- Machine availability and downtime.
- Material wastage and rejection percentage.
- Product quality compliance.
- Process parameter compliance.
- Start-up and changeover efficiency.
- GMP and housekeeping audit scores.
- Breakdown reporting and response.
- Accuracy of production documentation.

7. Skills and Competencies

- Strong technical and mechanical understanding.
- Good troubleshooting and problem-solving skills.
- Ability to work independently.
- Attention to detail and process discipline.
- Ability to work in rotational shifts, as required.
- Team coordination and communication.
- Commitment to quality, safety and production targets.

8. Safety and Compliance Responsibilities

- Follow machine safety procedures and authorized operating instructions.
- Never bypass machine guards or safety interlocks.
- Follow lockout/tagout (LOTO) procedures during maintenance-related activities.
- Ensure safe handling of hot surfaces, rotating components and moving machinery.
- Immediately report unsafe conditions and near-miss incidents.

Pay: From ₹25,000.00 per month

Work Location: In person

📌 Extruder Machine Operator (Harohalli (J))
🏢 PAGARIYA FOOD PRODUCT
📍 Harohalli (J)