Foam Machine Operator : Panel Line

Bcs Consulting; Mangaon; On-site; INR 350,000 - 520,000; Full time

Job summary

Bcs Consulting is seeking an experienced technician to operate and optimize continuous PUF/PIR sandwich panel lines in Maharashtra, India. You will monitor process parameters, perform in-process checks, and ensure batch traceability while following safety guidelines.

Ideal candidates have 3+ years on PUF/PIR lines, proficiency in ERP/MES data entry, and strong trouble-shooting skills to minimize downtime and improve yield and quality metrics.

Qualifications

• ITI / Diploma in Chemical, Mechanical, or Production Engineering.
• 3+ years of hands-on experience operating continuous PUF / PIR sandwich panel lines.
• Experience with ERP/MES data entry and basic root-cause analysis (5-Why, basic SPC).
• Exposure to sandwich panel / insulation manufacturing is a plus.

Responsibilities

• Set, control, and monitor mix ratios, temperatures, injection pressures, and line speed per recipes and SOPs.
• Perform and log tests for cream time, gel time, tack-free time, core density, peel adhesion, and surface quality.
• Manage polyol/pentane premix operations, FEFO, storage temps, filters, drum changes, and batch traceability.
• Assist line setup and changeovers to minimize downtime; balance line flow with downstream packaging sections.
• Follow pentane safety protocols, use PPE, maintain LOTO and spill responses.
• Troubleshoot issues like core voids or delamination via real-time parameter adjustments.
• Complete shift batch sheets, logs, and ERP/MES entries; drive improvements in FPY, yield, and OEE.

Skills

Process control

Quality testing

Root cause analysis

ERP/MES data entry

Precision measurement

Education

ITI / Diploma in Chemical/Mechanical/Production Engineering

Tools

Calipers & gauges

Tape measure

ERP/MES

Job description

Role & responsibilities :

• Process & Parameter Control: Set, control, and continuously monitor mix ratios/index (NCO:OH), raw material temperatures, injection pressures, and line speed in strict accordance with recipes and SOPs.
• Quality & In-Process Checks: Perform and log regular tests for cream time, gel time, tack-free time, core density, peel adhesion, and visual surface/bonding quality.
• Raw Material Handling: Manage polyol/pentane premix operations, enforce FEFO (First-Expired, First-Out), verify drum storage temperatures, clean strainers/filters, manage safe drum changes, and maintain batch traceability.
• Line Setup & Changeovers: Assist in seamless skin and thickness changeovers to minimize downtime; balance line flow with downstream double belt, saw, and packing sections.
• EHS & Pentane Safety Compliance: Strictly follow pentane safety protocols (explosion-proof/LEL monitors, earthing/bonding, ventilation systems), mandatory PPE usage, MSDS guidelines, Lockout/Tagout (LOTO), and chemical spill responses.
• Troubleshooting & Optimization: Identify abnormalities early to troubleshoot issues like core voids, delamination, foam scorching, and edge crush via real-time process parameter adjustments.
• Documentation & Continuous Improvement: Complete shift batch sheets, rejection tags, deviation logs, and ERP/MES data entries accurately; maintain 5S standards and drive improvements in First Pass Yield (FPY), raw material yield, and OEE.

Preferred candidate profile:

• Education: ITI / Diploma in Chemical, Mechanical, or Production Engineering.
• Experience: 3+ years of hands-on experience operating continuous PUF / PIR sandwich panel lines (exposure to mineral wool panels is a plus).
• Technical Skills: Deep understanding of continuous foam process control, density and peel-adhesion testing, precision measuring tools (calipers, gauges, tape), basic root cause analysis (5-Why, basic SPC), and operational data entry in ERP/MES.
• Preferred Background: Candidates with prior experience in sandwich panel / insulation manufacturing companies (e.g., EPACK, Metecno, Icemake, Alfa PEB, Everest Composites, RINAC, or similar).