Senior APC Engineer – Process Optimisation Applications (PXP)

453 Fuller Technologies Cement India LLP; Chennai District; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

Fuller Technologies Cement India LLP seeks a Senior APC Engineer to advance process optimisation using APC, AI/ML, and advanced control techniques across cement and mining operations. You will lead end-to-end APC projects from data analysis to commissioning and long-term performance support.

The role emphasizes hands-on model development, deployment, and continuous improvement, with frequent travel (40–60%) within India and internationally to support commissioning and training.

Qualifications

• Extensive hands-on experience in Advanced Process Control, data analytics, ML/AI applied to industrial processes.
• Experience in data mining, modelling, deployment and real-time implementation.
• Background in process manufacturing; cement/minerals knowledge is a plus.
• Strong understanding of optimisation and benefit analysis.
• Familiarity with industrial data connectivity and historians.

Responsibilities

• Perform process and data analysis on cement/mineral plants to identify optimisation opportunities.
• Design, test, and deploy predictive models and soft sensors using AI/ML.
• Implement, validate, and maintain real-time APC applications (MPC, AI/ML, fuzzy logic, PID).
• Estimate and quantify process improvements using data analytics for performance guarantees.
• Adapt and retrain models and controllers to maintain stability and performance.
• Define and implement APC strategies including configuration and commissioning.
• Fine-tune controllers to meet productivity and energy targets.
• Support system integration with PLCs, DCS, historians; hardware/software selection.
• Collaborate with project managers and customer teams to meet schedules.
• Provide training and mentoring on data analytics in ECS/ProcessExpert platform.
• Evaluate emerging analytics/non-linear modelling developments for improvement.
• Contribute to sales support, product development, testing and service.

Skills

APC

Data Analytics

Machine Learning

AI Applications

Tools

SQL

MQTT

PLCs

DCS

Databricks

Python

Job description

Senior APC Engineer – Process Optimisation Applications (PXP)

For more than 140 years, Fuller Technologies has helped industrial producers solve complex process challenges and operate more efficiently, reliably, and sustainably. Our success is built on two foundations: engineering excellence and long-standing partnerships with our customers. As a Senior APC Engineer, you will carry this legacy forward by applying advanced process control, analytics, and AI/ML technologies to cement and mining operations worldwide. At Fuller, APC engineering is not just about control algorithms — it is about understanding the process, earning customer trust, and delivering performance that lasts.

About the role

You will be part of Fullers Process Optimisation Team, working with the ECS/ProcessExpert® APC toolbox and advanced control techniques such as MPC and AI/ML. Your role focuses on delivering APC and soft-sensor solutions that stabilise plant operations, improve throughput, and reduce energy and fuel consumption. This is a hands-on technical role with responsibility across the full APC project lifecycle — from process analysis and model development to commissioning, optimisation, and long-term performance support.

Your Responsibilities

• Perform process and data analysis using historical and real‑time data from cement and minerals plants to identify optimisation opportunities.


• Design, develop, test, and deploy predictive models and soft sensors using linear and non‑linear AI/ML algorithms.


• Implement, validate, and maintain real‑time APC applications using MPC, AI/ML, fuzzy logic, and PID control strategies.


• Estimate and quantify process improvement benefits using data analytics, supporting performance guarantees and technical proposals.


• Adapt, tune, and retrain models and controllers to ensure sustained performance and operational stability.


• Define and implement process control strategies, including configuration and commissioning of APC solutions.


• Fine‑tune MPC, fuzzy, and PID controllers to achieve guaranteed performance targets related to productivity, energy efficiency, and stability.


• Support system integration activities, including hardware selection, software installation, and connectivity with PLCs, DCS, and historians.


• Collaborate with project managers and customer teams to ensure APC projects are delivered on schedule and to specification.


• Provide training and technical mentoring to APC engineers on data analytics and AI/ML applications within the ECS/ProcessExpert® platform.


• Evaluate emerging developments in advanced analytics and non‑linear modelling to continuously improve APC applications.


• Contribute across the broader APC lifecycle, including sales support, product development, feature testing, and service support as required.

What You Bring

• Strong hands‑on experience in Advanced Process Control, Data Analytics, Machine Learning, and AI applied to industrial processes.


• Proven experience in data mining, statistical modelling, model deployment, and real‑time implementation.


• Background in process manufacturing industries; cement and minerals process knowledge is a strong advantage.


• Solid understanding of process optimisation, control strategy development, and benefit analysis.


• Experience with industrial data connectivity and historians, including SQL, MQTT, PLCs, DCS, and modern data platforms.


• Familiarity with AI/ML and data analytics tools commonly used in process industries, including: Python, Pandas, NumPy, Scikit‑Learn, TensorFlow, Matplotlib, Seaborn, Databricks.


• Willingness to travel (40–60%) within India and internationally for commissioning, pilot testing, customer engagement, and training.

Company Culture

Build a better world Fuller Technologies helps build societies all over the world by contributing to the infrastructure needed for global economic growth. It is a big responsibility, and we are committed to driving growth while minimising environmental impact. To achieve this, your skills, your curiosity, and your drive for change are important. Together in our diverse team, we collaborate in an inclusive and supportive environment to discover further ways to economic and environmental success.

For further information on Fuller Technologies' business and services, visit https://www.fuller-technologies.com/. Fuller is a Cement technology and service supplier with a passion to help our customers produce cement efficiently. After 140+ years of pioneering new innovations, we are uniquely positioned to be at the forefront of our industry’s green transition.