Process Operator - 3rd shift

Barcel USA; Coppell (TX); On-site; USD 42,000 - 66,000; Full time

Job summary

Barcel USA in Coppell, TX is seeking a Process Operator to ensure safe, efficient production and to safeguard product quality. You will monitor critical process parameters, operate mixers, ovens, fryers, and stabilizers, and work with QA to minimize waste and maintain GMP/HACCP compliance.

The role requires mechanical aptitude, a safety focus, and the ability to support continuous improvement across production lines. Shifts may include weekends.

Qualifications

• High School Diploma or GED required.
• 2+ years in manufacturing, preferably in food processing.
• Experience operating industrial mixers, ovens, or fryers preferred.

Responsibilities

• Adhere to plant safety regulations and wear PPE; apply LOTO procedures.
• Monitor critical parameters to ensure quality and food safety; reduce waste.
• Operate and monitor processing equipment per SOPs (mixers, ovens, fryers, stabilizers).
• Report equipment malfunctions and coordinate with maintenance and supervisors.
• Record production data and support 5S and continuous improvement initiatives.
• Collaborate with QA to address non-conformances and prevent waste.
• Serve as SME during audits, training sessions and process changes.

Skills

Safety compliance

Quality control

Equipment operation

Troubleshooting

Waste reduction

Documentation

Education

High School Diploma or GED

Tools

Industrial mixers

Ovens

Fryers

Job description

Job Purpose

The Process Operator is responsible for ensuring the efficient, safe, and compliant operation of production equipment within the production line. This role serves as a technical expert on the line, monitoring critical parameters to guarantee product quality and food safety while actively identifying opportunities to minimize waste. The ideal candidate possesses strong mechanical aptitude, a commitment to safety, and a focus on operational efficiency through waste reduction.

Job Purpose

The Process Operator is responsible for ensuring the efficient, safe, and compliant operation of production equipment within the production line. This role serves as a technical expert on the line, monitoring critical parameters to guarantee product quality and food safety while actively identifying opportunities to minimize waste. The ideal candidate possesses strong mechanical aptitude, a commitment to safety, and a focus on operational efficiency through waste reduction.

Duties and responsibilities

• Safety & Compliance
• Strictly adhere to all plant safety regulations, including the consistent wearing of required Personal Protective Equipment (PPE) and rigorous application of Lockout/Tagout (LOTO) procedures.
• Actively identify, report, and assist in mitigating safety hazards or non-compliance issues within the process area to maintain a zero-incident workplace.
• Promote a proactive culture of safety by modeling best practices
• Quality Control
• Continuously monitor and validate critical process parameters - such as moisture levels, oil absorption, temperature, Free Fatty Acids (FFAs), and dough consistency to ensure finished products meet internal and regulatory specifications.
• Perform regular quality checks and document results for key metrics, including:
• Water temperature
• Mixing time
• Dough moisture
• Moisture levels after oven/stabilizer
• Oil absorption (for fried products)
• Final product texture (e.g., Takis texture)

Collaborate closely with the Quality Assurance (QA) department to address non-conformances immediately and implement effective corrective actions to prevent product waste.

Ensure full compliance with Good Manufacturing Practices (GMPs), Hazard Analysis Critical Control Point (HACCP) principles, and FDA regulations at all times.

• Equipment Operation & Maintenance
• Safely operate and monitor all processing equipment—including mixers, ovens, fryers, and stabilizers—in accordance with Standard Operating Procedures (SOPs).
• Perform basic troubleshooting and make precise adjustments to machinery to minimize downtime, reduce scrap, and maintain product flow.
• Promptly report equipment malfunctions or unusual wear to the maintenance team and production supervisors.
• Process Improvement & Documentation
• Accurately record all production data, equipment settings, and process deviations in the GB connected.
• Actively support 5S initiatives to ensure work areas remain clean, organized, and efficient, which directly contributes to waste reduction.
• Identify opportunities for process optimization (e.g., reducing ingredient waste, minimizing product giveaways, improving efficiency) and contribute ideas to continuous improvement projects.
• Maintain clear and effective communication by participating in production loops, including shift handovers.
• Leadership & Collaboration
• Guide on daily tasks and managing complex operational scenarios, with an emphasis on efficiency and waste reduction.
• Work cross-functionally with Production Supervisors, QA, and Maintenance teams to resolve issues quickly and meet daily production targets without sacrificing quality or creating excess waste.
• Serve as a subject-matter expert (SME) for the process area, providing insight and guidance during audits, training sessions, and process changes.

Qualifications

Education & Experience:

• High School Diploma or GED required.
• 2+ years of experience in a manufacturing environment, preferably in food processing.
• Previous experience operating industrial mixers, ovens, or fryers is highly preferred.

Skills & Competencies

• Strong understanding of GMP, HACCP, and food safety regulations.
• Mechanical aptitude with the ability to troubleshoot basic equipment issues.
• Demonstrated ability to identify and reduce waste in a production environment.
• Ability to read and interpret documents such as safety rules, operating manuals, and SOPs.
• Proficiency in basic math and documentation skills.
• Ability to work in a team environment and lead by example.
• Flexibility to work various shifts, including weekends and holidays, as required.

Physical Requirements

• Ability to stand for extended periods and walk long distances throughout the shift.
• Ability to work in varying temperatures (heat/cold) and around loud machinery.
• Must be able to lift up to [e.g., 50 lbs] and perform physical tasks such as bending, reaching, and climbing.