Process Engineer (6th of October)

Job Title:Process EngineerReports To: Production ManagerBusiness Unit: ACCBCFunction: Manufacturing / OperationsLocation: 6th October Area, Cairo, EgyptGrade: TBCJob PurposeTo operate, monitor, and optimise juice production processes – including water treatment, syrup preparation, and production line management – ensuring efficient output, consistent product quality, and full compliance with food safety and HSE standards.Operating ContextThe Process Engineer operates within a fast-moving FMCG beverage manufacturing environment, working across production, water treatment, and syrup preparation areas. The role operates under the following conditions:Multi-Process Manufacturing Environment: Production processes span mixing, blending, pasteurisation, and homogenisation, requiring precise parameter setting and continuous monitoring to maintain product quality and line efficiency.Food Safety & CCP Discipline: Critical Control Points (CCPs) must be actively tracked and recorded throughout each production run, with any deviation requiring immediate escalation and corrective action.Maintenance Coordination: Equipment reliability directly impacts production continuity, requiring close coordination with the maintenance team for both corrective and preventive maintenance activities.Regulatory & Safety Standards: Compliance with HACCP, GMP, and HSE standards is non-negotiable and applies across all areas of the production facility at all times.Key Roles and ResponsibilitiesA. Production Process Operation & Monitoring• Operate and monitor production processes including mixing, blending, pasteurisation, and homogenisation.• Set and adjust production line parameters through PLC/HMI systems in line with product specifications and requirements.• Monitor production performance continuously, recording data and tracking Critical Control Points (CCPs) throughout each production run.• Identify and escalate process deviations immediately, applying corrective actions to maintain product quality and output targets.B. Water Treatment & Syrup Preparation• Oversee water treatment plant operations, ensuring water quality meets production and regulatory standards.• Manage syrup preparation activities including sugar dissolving, ensuring accurate formulation and hygiene compliance.• Monitor water treatment parameters and syrup preparation outputs, recording results and flagging deviations to the Production Manager.C. Operator Supervision & Production Flow• Supervise production operators, ensuring all tasks are performed correctly, safely, and in accordance with standard operating procedures.• Ensure smooth and uninterrupted production flow by coordinating operator activities and resolving operational issues in real time.• Conduct shift briefings and ensure operators are informed of production targets, quality requirements, and safety protocols.D. Equipment Cleanliness & Sanitation• Ensure cleanliness and sanitation of tanks, equipment, and all production areas in line with GMP and food safety standards.• Oversee and verify cleaning-in-place (CIP) and cleaning-out-of-place (COP) procedures are completed correctly and documented.• Maintain a zero-compromise standard for equipment hygiene and production area sanitation at all times.E. Maintenance Coordination• Coordinate with the maintenance team to ensure timely response to equipment breakdowns and repairs.• Follow up on preventive maintenance schedules, ensuring planned maintenance activities are completed without impacting production continuity.• Raise maintenance requests promptly and track resolution to minimise downtime.F. Troubleshooting & Root Cause Analysis• Troubleshoot production issues as they arise, applying structured problem-solving techniques to identify and resolve root causes.• Conduct or contribute to root cause analysis (RCA) for recurring issues, equipment failures, or quality deviations.• Document findings and corrective actions, sharing learnings with the Production Manager and relevant teams to prevent recurrence.G. Food Safety, HSE & Continuous Improvement• Ensure full compliance with food safety standards including HACCP and GMP across all production activities.• Adhere to and enforce HSE requirements across the production area, reporting hazards, near misses, and incidents without delay.• Actively participate in continuous improvement initiatives including 5S and Kaizen, contributing to reductions in downtime, waste, and process inefficiency.Key Performance Indicators (KPIs)Production & Quality• Production line efficiency and output vs target• CCP compliance rate – zero unrecorded or unresolved CCP deviations• Product quality conformance rate per batchFood Safety & HSE• Zero HACCP or GMP non-conformances attributable to process operation• HSE incident and near-miss reporting rate – all incidents reported within shift• Sanitation and CIP/COP completion rate – 100% per scheduleEquipment & Efficiency• Equipment downtime attributable to process handling – minimised and tracked• Preventive maintenance follow-up completion rate• Waste and raw material loss rate vs targetRequired Experience and QualificationsMinimum Qualifications• Bachelor’s degree in Science, Food Technology, Agriculture, Chemical Engineering, or a related field.• Knowledge of food safety standards (HACCP, GMP) is required.• Basic proficiency in PLC/HMI systems is an advantage.Minimum Experience• Minimum 1–3 years of experience in FMCG manufacturing, preferably in the food or beverage industry.• Hands-on experience operating or monitoring production processes in a manufacturing environment.• Exposure to water treatment, syrup preparation, or similar process operations is an advantage.Knowledge and Skills• Basic knowledge of production processes including mixing, blending, pasteurisation, and homogenisation.• Understanding of food safety standards including HACCP and GMP.• Problem-solving and analytical ability for troubleshooting production issues and conducting root cause analysis.• Leadership and teamwork skills for supervising operators and coordinating with maintenance and quality teams.• Attention to detail in data recording, CCP monitoring, and process parameter management.