TetraPak Filling Operator

Purpose

Support product changeovers and smooth line running. Operate, monitor, and maintain the UHT processing line to ensure consistent, safe, and high-quality production.

Key Responsibilities

Machine Operation

·      Operate Tetra Pak filling machine (A3 Flex/TBA8 or equivalent).

·      Start-up and shut down machine according to SOP.

·      Carry out aseptic production following standard procedures.

·      Monitor machine parameters throughout production.

·      Maintain production speed according to production plan.

·      Ensure continuous product flow without unnecessary stoppages.

Production Activities

·      Prepare machine before production.

·      Perform package size changeovers.

·      Load packaging material and caps.

·      Monitor filling accuracy.

·      Verify package integrity.

·      Monitor coding and date printing.

·      Maintain production records.

Quality Control

·      Perform hourly quality checks.

·      Check package seal quality.

·      Monitor package appearance.

·      Verify fill volume.

·      Conduct leak tests.

·      Reject defective packs.

·      Report quality deviations immediately.

Food Safety

·      Follow GMP requirements.

·      Follow HACCP procedures.

·      Maintain aseptic conditions.

·      Prevent contamination.

·      Ensure sanitation standards are maintained.

·      Wear appropriate PPE.

Machine Monitoring

Monitor:

·      Sterilization temperatures

·      Hydrogen peroxide concentration

·      Air pressure

·      Steam pressure

·      Product temperature

·      Filling accuracy

·      Machine alarms

·      Packaging material usage

Minor Maintenance

·      Perform daily autonomous maintenance.

·      Clean machine externally.

·      Lubricate designated parts.

·      Replace minor consumables.

·      Assist maintenance during breakdowns.

·      Report abnormal noises or vibrations.

Housekeeping

·      Maintain cleanliness around machine.

·      Follow 5S principles.

·      Dispose of waste correctly.

·      Keep work area organized.

Documentation

Maintain records of:

·      Production quantity

·      Downtime

·      Rejections

·      Machine stoppages

·      Material consumption

·      Shift handover

·      Cleaning records

Key Performance Indicators (KPIs)

·      Production efficiency (%)

·      OEE

·      Downtime

·      Product loss (%)

·      Packaging material loss

·      First Pass Yield

·      Number of quality defects

·      Customer complaints

·      Food safety compliance

·      GMP compliance

·      Machine availability

·      Housekeeping score

  KEY QUALIFICATIONS & REQUIREMENTS

·      ITI/Diploma – Mechanical/Electrical/ Food Technology or Industrial Engineering.

·      Hands-on Filling Machine operation experience (Tetra Pak, Elecster, Alps ).

·      3–5 years’ operating Tetra Pak aseptic filling machines.

·      Experience in beverage, dairy, juice or UHT processing.