Manager Production (Integrated Cement Plant)

Sarthee Consultancy; Navi Mumbai; On-site; INR 700,000 - 1,100,000; Full time

Job summary

Sarthee Consultancy is seeking a seasoned cement plant process specialist to drive daily production of limestone crushing, raw mill, kiln and cement grinding sections. You will optimize heat and mass balances, ensure stable kiln operation and clinker quality while coordinating with Mines, Maintenance and Quality teams.

The role demands deep knowledge of VRM and ball mill operations, dust collection systems, and ISO management systems to enhance efficiency and reliability across the plant.

Qualifications

• Bachelors in Chemistry or Chemical Engineering is required.
• Strong knowledge of cement plant processes and energy efficiency.
• Experience in heat and mass balance, kiln and grinding systems desired.

Responsibilities

• Coordinate daily production targets for limestone crushing, raw mill, kiln/pyro section and cement grinding.
• Optimize kiln feed chemistry for stable operation and clinker quality.
• Maintain clinker factor and cement blending targets.
• Collaborate with Mines, Maintenance, Quality, Purchase, Stores and Finance for reliable plant performance.

Skills

Heat balance

Mass balance

Raw mix design

Kiln operation

VRM operation

Ball mill optimization

Dust collection systems

ISO systems

DCS/PLC control

Quality control coordination

Education

BSC Chemistry

BE Chemical

Tools

QCX/Lab systems

DCS/PLC process control

Job description

Education

• BSC Chemistry or BE Chemical

Technical & Process Expertise

• Deep knowledge of:
  • Raw Mix design & proportioning
  • Heat & Mass Balance calculations
  • Kiln pyro-processing & clinkerization chemistry
  • VRM and Ball Mill operation & optimization
  • Coal mill operation and fuel optimization
  • Clinker cooler efficiency improvement
• Strong understanding of:
  • Refractory selection, installation & performance monitoring
  • Grinding media optimization
  • Dust collectors, ESPs & Bag Filters
  • Alternative fuels & thermal substitution rate (TSR)
• Working knowledge of:
  • QCX / Laboratory systems
  • DCS/PLC based process control systems
  • Cement quality standards & statutory norms
  • ISO 9001 / ISO 14001 / ISO 45001 systems

Operational & Leadership Capabilities

• Strong cross-functional coordination with:
  • Mines
  • Maintenance (Mechanical + E&I)
  • Quality Control
  • Purchase & Stores
  • Finance
• Proven track record of:
  • Reducing Heat Consumption (kCal/kg clinker)
  • Reducing Power Consumption (kWh/ton cement)
  • Increasing Kiln availability & output
• Budget preparation and cost optimization skills.
• Strong MIS, ERP and KPI monitoring capability.

Production Planning & Execution

• Ensure daily, monthly & annual production targets for:
  • Limestone crushing
  • Raw Mill
  • Kiln & Pyro section
  • Cement grinding
• Optimize kiln feed chemistry and ensure stable operation.
• Maintain clinker factor and cement blending targets.
• Coordinate closely with Mines team for raw material availability and quality alignment.
• Ensure plant runs at optimum rated capacity with maximum reliability.