Senior Filling & Packaging Technician (Tetra Pak A3/Flex)

Farm Fresh Central; Negeri Sembilan; On-site; MYR 78,000 - 123,000; Full time

Job summary

Farm Fresh Enstek in Malaysia is seeking a Senior Technician to ensure the technical performance, uptime and food safety of the Tetra Pak A3/Flex filling line. The role covers both A3/Flex filling and downstream equipment, ensuring stable aseptic operation, fast changeovers and GMP/HACCP/EHS compliance.

You will lead maintenance, coordinate with QA, mentor junior staff and drive OEE, MTBF and downtime reduction while adhering to safety standards.

Qualifications

• Diploma or degree in Mechanical, Electrical, Mechatronics or Food Engineering.
• 5–8 years hands-on experience with Tetra Pak A3/Flex in dairy/liquid foods.
• Experience with Helix straw applicator, CAP30F, CBP packer.
• Aseptic processing, CIP/SIP, GMP/HACCP/EHS knowledge.
• Read P&IDs & electrical schematics; know OEM manuals.
• PLC/HMI fault-finding (Siemens/AB).
• Bahasa Malaysia and English; MS Office proficient.

Responsibilities

• Operate, monitor and maintain the Tetra Pak A3/Flex filling machine ensuring stable aseptic conditions and package integrity.
• Operate and maintain downstream equipment: Helix straw applicator, CAP30F cap applicator and CBP cardboard packer; ensure tight integration with the FM.
• Lead sterilisation, production, intermediate cleaning and CIP/SIP cycles of the line as per Tetra Pak / Farm Fresh SOPs.
• Execute fast, accurate product, packaging-material and format changeovers; minimise changeover time and packaging-material waste.
• Diagnose and resolve mechanical, electrical, pneumatic and process issues on FM and DE; perform first-line repairs and elevate complex failures.
• Plan and execute preventive maintenance, daily/weekly/monthly service kits and overhauls following Tetra Pak service-management recommendations.
• Monitor and drive key indicators: OEE, package integrity (TAA, drop test, seal test), MTBF, MTTR, waste, downtime reasons.
• Maintain accurate documentation: shift logs, batch records, aseptic challenge tests, CIP/SIP records, package-integrity test results, spare-parts consumption.
• Coach junior technicians and operators on safe operation, aseptic discipline and basic troubleshooting on FM, Helix, CAP30F and CBP.
• Coordinate with QA/QC on package integrity tests, microbiological results, deviations and CAPA.

Skills

Leadership

Troubleshooting

P&ID reading

PLC fault-finding

HMI fault-finding

MS Office

Team coaching

Education

Engineering degree

Job description

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Senior technician responsible for the technical performance, uptime and food safety of the Tetra Pak A3/Flex filling line at Farm Fresh Enstek. The role covers both the A3/Flex filling machine and Tetra Pak downstream equipment (Helix straw applicator, CAP30F, CBP cardboard packer), ensuring stable aseptic operation, fast changeover and strict GMP/HACCP/EHS compliance.

Key responsibilities

Operate, monitor and maintain the Tetra Pak A3/Flex filling machine ensuring stable aseptic conditions and package integrity.

Operate and maintain Tetra Pak downstream equipment: Helix straw applicator, CAP30F cap applicator and CBP cardboard packer; ensure tight integration with the FM.

Lead sterilisation, production, intermediate cleaning and CIP/SIP cycles of the line as per Tetra Pak / Farm Fresh SOPs.

Execute fast, accurate product, packaging-material and format changeovers; minimise changeover time and packaging-material waste.

Diagnose and resolve mechanical, electrical, pneumatic and process issues on FM and DE; perform first-line repairs and elevate complex failures.

Plan and execute preventive maintenance, daily/weekly/monthly service kits and overhauls following Tetra Pak service-management recommendations.

Monitor and drive key indicators: OEE, package integrity (TAA, drop test, seal test), MTBF, MTTR, waste, downtime reasons.

Maintain accurate documentation: shift logs, batch records, aseptic challenge tests, CIP/SIP records, package-integrity test results, spare-parts consumption.

Coach junior technicians and operators on safe operation, aseptic discipline and basic troubleshooting on FM, Helix, CAP30F and CBP.

Coordinate with QA/QC on package integrity tests, microbiological results, deviations and CAPA.

About you

Diploma / Degree in Mechanical, Electrical, Mechatronics, Food Engineering or related discipline.

Minimum 5-8 years of hands-on experience on Tetra Pak A3/Flex (or equivalent TBA/A1/A3) filling machines in a dairy, beverage or liquid food environment.

Demonstrated experience with Tetra Pak downstream equipment: Helix straw applicator, CAP30F, CBP cardboard packer.

Strong working knowledge of aseptic processing, sterilisation cycles, CIP/SIP and aseptic-zone integrity.

Solid mechanical, electrical and pneumatic troubleshooting skills; able to read P&IDs, electrical schematics and Tetra Pak OEM manuals.

Exposure to PLC / HMI fault-finding (Siemens / Allen-Bradley) and basic instrumentation.

Knowledge of GMP, HACCP, ISO 22000, HALAL and EHS standards.

Strong leadership, mentoring and problem-solving skills; able to lead a shift team.

Willing to work on rotating shift, weekends and public holidays.

Proficient in Bahasa Malaysia and English; competent in MS Office.