Senior APC Engineer – Process Optimisation Applications (PXP)

Fuller; Chennai District; On-site; INR 1,800,000 - 3,000,000; Full time

Job summary

Fuller Technologies seeks a Senior APC Engineer to advance process control through AI/ML and analytics across cement and minerals operations worldwide.

You will work with the ECS/ProcessExpert APC toolbox, applying MPC, AI/ML, and soft sensors to stabilise plants, improve throughput, and cut energy use. Travel and collaboration with customers are involved.

Qualifications

• Hands-on experience in Advanced Process Control and AI for industrial processes.
• Proven data mining, statistical modelling, and real-time deployment.
• Background in cement and minerals processes is a plus.

Responsibilities

• Analyze process data from cement and minerals plants to identify opportunities.
• Develop and test predictive models and soft sensors.
• Implement real-time APC applications using MPC and AI/ML.
• Quantify process improvements with data analytics for proposals.
• Tune MPC, fuzzy, and PID controllers for performance targets.
• Coordinate with PLC/DCS historians during system integration.

Skills

Advanced Process Control

Data Analytics

Machine Learning

AI for Industry

Data Mining

Statistical Modelling

Model Deployment

Real-time Control

Industrial Data Connectivity

Python

Tools

SQL

MQTT

PLCs

DCS

Python

Pandas

NumPy

Scikit-Learn

TensorFlow

Databricks

Job description

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.

As an equal opportunity employer, Fuller Technologies embraces diversity and equality by promoting an environment of inclusion. We encourage applicants of all backgrounds to apply irrespective of sex, gender identity/expression, disability, sexual orientation, or age. The more diverse our employees are, the stronger

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/