Process Engineer (6th of October)

Job Title:Process Engineer

Reports To: Production Manager

Business Unit: ACCBC

Function: Manufacturing / Operations

Location: 6th October Area, Cairo, Egypt

Grade: TBC

Job Purpose

To operate, monitor, and optimise juice production processes – including water treatment, syrup preparation, and production line management – ensuring efficient output, consistent product quality, and full compliance with food safety and HSE standards.

Operating Context

The Process Engineer operates within a fast-moving FMCG beverage manufacturing environment, working across production, water treatment, and syrup preparation areas. The role operates under the following conditions:

• Multi-Process Manufacturing Environment: Production processes span mixing, blending, pasteurisation, and homogenisation, requiring precise parameter setting and continuous monitoring to maintain product quality and line efficiency.
• Food Safety & CCP Discipline: Critical Control Points (CCPs) must be actively tracked and recorded throughout each production run, with any deviation requiring immediate escalation and corrective action.
• Maintenance Coordination: Equipment reliability directly impacts production continuity, requiring close coordination with the maintenance team for both corrective and preventive maintenance activities.
• Regulatory & Safety Standards: Compliance with HACCP, GMP, and HSE standards is non-negotiable and applies across all areas of the production facility at all times.

Key Roles and Responsibilities

A. Production Process Operation & Monitoring

• Operate and monitor production processes including mixing, blending, pasteurisation, and homogenisation.

• Set and adjust production line parameters through PLC/HMI systems in line with product specifications and requirements.

• Monitor production performance continuously, recording data and tracking Critical Control Points (CCPs) throughout each production run.

• Identify and escalate process deviations immediately, applying corrective actions to maintain product quality and output targets.

B. Water Treatment & Syrup Preparation

• Oversee water treatment plant operations, ensuring water quality meets production and regulatory standards.

• Manage syrup preparation activities including sugar dissolving, ensuring accurate formulation and hygiene compliance.

• Monitor water treatment parameters and syrup preparation outputs, recording results and flagging deviations to the Production Manager.

C. Operator Supervision & Production Flow

• Supervise production operators, ensuring all tasks are performed correctly, safely, and in accordance with standard operating procedures.

• Ensure smooth and uninterrupted production flow by coordinating operator activities and resolving operational issues in real time.

• Conduct shift briefings and ensure operators are informed of production targets, quality requirements, and safety protocols.

D. Equipment Cleanliness & Sanitation

• Ensure cleanliness and sanitation of tanks, equipment, and all production areas in line with GMP and food safety standards.

• Oversee and verify cleaning-in-place (CIP) and cleaning-out-of-place (COP) procedures are completed correctly and documented.

• Maintain a zero-compromise standard for equipment hygiene and production area sanitation at all times.

E. Maintenance Coordination

• Coordinate with the maintenance team to ensure timely response to equipment breakdowns and repairs.

• Follow up on preventive maintenance schedules, ensuring planned maintenance activities are completed without impacting production continuity.

• Raise maintenance requests promptly and track resolution to minimise downtime.

F. Troubleshooting & Root Cause Analysis

• Troubleshoot production issues as they arise, applying structured problem-solving techniques to identify and resolve root causes.

• Conduct or contribute to root cause analysis (RCA) for recurring issues, equipment failures, or quality deviations.

• Document findings and corrective actions, sharing learnings with the Production Manager and relevant teams to prevent recurrence.

G. Food Safety, HSE & Continuous Improvement

• Ensure full compliance with food safety standards including HACCP and GMP across all production activities.

• Adhere to and enforce HSE requirements across the production area, reporting hazards, near misses, and incidents without delay.

• Actively participate in continuous improvement initiatives including 5S and Kaizen, contributing to reductions in downtime, waste, and process inefficiency.

Key Performance Indicators (KPIs)

Production & Quality

• Production line efficiency and output vs target

• CCP compliance rate – zero unrecorded or unresolved CCP deviations

• Product quality conformance rate per batch

Food Safety & HSE

• Zero HACCP or GMP non-conformances attributable to process operation

• HSE incident and near-miss reporting rate – all incidents reported within shift

• Sanitation and CIP/COP completion rate – 100% per schedule

Equipment & Efficiency

• Equipment downtime attributable to process handling – minimised and tracked

• Preventive maintenance follow-up completion rate

• Waste and raw material loss rate vs target

Required Experience and Qualifications

Minimum Qualifications

• Bachelor's degree in Science, Food Technology, Agriculture, Chemical Engineering, or a related field.

• Knowledge of food safety standards (HACCP, GMP) is required.

• Basic proficiency in PLC/HMI systems is an advantage.

Minimum Experience

• Minimum 1–3 years of experience in FMCG manufacturing, preferably in the food or beverage industry.

• Hands-on experience operating or monitoring production processes in a manufacturing environment.

• Exposure to water treatment, syrup preparation, or similar process operations is an advantage.

Knowledge and Skills

• Basic knowledge of production processes including mixing, blending, pasteurisation, and homogenisation.

• Understanding of food safety standards including HACCP and GMP.

• Problem-solving and analytical ability for troubleshooting production issues and conducting root cause analysis.

• Leadership and teamwork skills for supervising operators and coordinating with maintenance and quality teams.

• Attention to detail in data recording, CCP monitoring, and process parameter management.