Spray Dryer Operator

Position

Spray Dryer Operator

Department

Production / Manufacturing

Qualification

Diploma in Engineering Mechanical / Electrical / Chemical or related discipline. (Preferred but can be waived off for experience of 6+ years)

Job Purpose

To safely and efficiently operate, monitor and maintain the Spray Dryer system with a capacity of approximately 600 kg/hour, ensuring consistent production, optimum process parameters, product quality, equipment reliability and adherence to safety procedures.

Key Responsibilities

1. Spray Dryer Operation & Maintenance

• Operate and monitor the Spray Dryer with a production capacity of approximately 600 kg/hour.
• Ensure smooth and continuous operation of the Spray Dryer and associated equipment.
• Carry out routine operational checks and basic preventive maintenance to ensure equipment availability and reliability.
• Identify abnormal operating conditions and promptly report equipment or process-related issues to the concerned supervisor/maintenance team.

1. HAG Firing & Temperature Control

• Operate and monitor the HAG (Hot Air Generator and maintain firing at the required level.
• Maintain appropriate temperature and airflow conditions to ensure a constant and controlled outflow of material from the Spray Dryer.
• Monitor fuel/firing conditions and make necessary adjustments within the prescribed operating parameters.

1. Atomiser Operation

• Possess good working knowledge of the atomiser system used in the Spray Dryer.
• Monitor atomiser operation, speed and performance to achieve consistent atomisation and product quality.
• Identify abnormal vibration, noise, temperature or other operating conditions and take appropriate corrective action/report the same.

2. Electrical Panel & VFD Operation

• Operate the electrical control panel associated with the Spray Dryer.
• Have working knowledge of VFD-controlled motors and their operating parameters.
• Monitor and operate multiple motors, including motors in the range of approximately 40–60 HP, operating simultaneously as part of the Spray Dryer system.
• Monitor motor load, current, frequency, alarms and other relevant electrical parameters and coordinate with the maintenance team whenever required.

3. Manpower Coordination & Job Execution

• Effectively coordinate with and get required work executed through down-the-line operators/helpers/workmen.
• Allocate work, monitor performance and ensure that assigned activities are completed safely and efficiently.
• Ensure proper coordination between production, maintenance and other supporting personnel.

4. Sealing Machine Operation

• Possess working knowledge of sealing machine operation for packing/handling of the finished product.
• Ensure proper operation of the sealing machine and report any abnormalities affecting packing quality or production.

5. Process Parameter Control

• Monitor and control various Spray Dryer process parameters as per the prescribed operating standards/SOPs.
• Maintain parameters such as inlet temperature,outlet temperature, feed rate, atomiser speed, airflow, pressure, HAG firing and other relevant parameters within specified limits.
• Make necessary process adjustments to maintain consistent product quality and production output.

6. Main Chamber & Cyclone Operation

• Possess sound working knowledge of the main drying chamber and cyclone system.
• Monitor the operation of the chamber and cyclone for efficient drying and powder recovery.
• Identify blockages, abnormal pressure, powder accumulation or other operational issues and take corrective action as per SOP.

7. Safety & Compliance

• Follow all applicable plant safety procedures, SOPs, GMP requirements and work instructions.
• Ensure safe operation of the Spray Dryer, HAG, electrical panels, motors, atomiser, cyclone and associated equipment.
• Use appropriate PPE and immediately report unsafe conditions, equipment abnormalities or safety incidents.
• Maintain proper housekeeping around the Spray Dryer and associated operating areas.

8. Production & Documentation

• Achieve production targets while maintaining required product quality and process efficiency.
• Maintain accurate records of production, process parameters, equipment operation, downtime and abnormalities.
• Ensure proper shift handover and communicate all important operational issues to the incoming shift/operator.

Required Skills & Competencies

• Strong practical knowledge of Spray Dryer operation.
• Good understanding of atomiser operation and maintenance.
• Working knowledge of HAG/Hot Air Generator operation and firing control.
• Ability to operate electrical control panels and VFD-controlled motors.
• Good understanding of temperature, airflow, pressure, feed rate and other process parameters.
• Working knowledge of main chamber and cyclone operation.
• Working knowledge of sealing/packing machine operation.
• Ability to supervise and coordinate operators/helpers and get work executed through the team.
• Ability to troubleshoot routine operational problems.
• Good understanding of industrial safety practices.
• Ability to work in shifts and under production targets.

Preferred Industry Experience

Candidates with experience in the following industries will be preferred:

• Dairy
• Nutraceuticals / Supplements
• Food Processing
• Chemical
• Pharmaceutical / allied manufacturing

Key Performance Expectations

The incumbent will be expected to:

• Operate the Spray Dryer safely and efficiently at the required production capacity.
• Maintain stable and consistent process parameters.
• Ensure consistent product quality and powder recovery.
• Minimise equipment downtime and process losses.
• Ensure proper operation of the HAG, atomiser, main chamber, cyclone and associated equipment.
• Maintain accurate production and operational records.
• Ensure compliance with safety, SOP and housekeeping requirements.