JOB DESCRIPTION – CPVC THEYSON EXTRUSION LINE OPERATOR / TECHNICIANPosition
CPVC Theyson Extrusion Line Operator / Senior Machine Operator
Department
Production – CPVC Pipe Manufacturing
Location
Gouri Aqua Plast / Ganesh Gouri Industries – Nagpur, Maharashtra
Reporting To
Production Manager / Plant Head
Experience
3–8 years of relevant experience in CPVC pipe extrusion
Mandatory: Hands-on experience operating a Theyson/Conical Twin-Screw CPVC extrusion line or equivalent CPVC pipe extrusion machinery.
1. Job Purpose
The primary responsibility of the CPVC Extrusion Line Operator is to independently operate and monitor the complete CPVC pipe extrusion line to achieve consistent production output, dimensional accuracy, surface finish and quality, while maintaining optimum machine efficiency and minimum material wastage.
The candidate will be responsible for the complete extrusion process from raw material feeding to finished pipe cutting, socketing and packing, wherever applicable.
The operator must have strong knowledge of CPVC processing parameters and should be capable of troubleshooting common extrusion defects and maintaining stable production conditions.
2. Key ResponsibilitiesA. Machine Operation
- Operate CPVC Theyson/Conical Twin-Screw Extrusion Machine independently.
- Start, operate and shut down the complete extrusion line according to SOP.
- Operate and monitor:
- Extruder
- Hopper and feeding system
- Conical twin-screw system
- Die head
- Vacuum calibration tank
- Cooling tank
- Haul-off unit
- Cutting machine
- Belling/socketing machine
- Online printer/marking system
- Auxiliary equipment
- Maintain stable production parameters throughout the shift.
- Ensure smooth and continuous extrusion with minimum line stoppages.
B. CPVC Process Parameter Control
The operator should be capable of setting and monitoring:
- Barrel temperature zones
- Die temperature zones
- Adapter temperature
- Screw RPM
- Feeder RPM
- Material feeding rate
- Melt pressure
- Melt temperature
- Vacuum pressure
- Cooling-water temperature
- Haul-off speed
- Cutter speed
- Pipe wall thickness
- Pipe OD and ID
- Production output in kg/hour or metres/hour
The candidate should understand the relationship between screw speed, feeding rate, temperature profile and output.
C. Production & Output Management
- Achieve daily and monthly production targets.
- Maintain the required output rate without compromising product quality.
- Optimize machine speed and process parameters to achieve maximum sustainable output.
- Monitor actual production against planned production.
- Minimize:
- Start-up scrap
- Process scrap
- Rejection
- Pipe deformation
- Off-specification production
- Maintain accurate shift-wise production records.
3. Quality Control Responsibilities
The operator will be responsible for maintaining consistent quality during production.
Regularly monitor:
- Pipe outer diameter
- Wall thickness
- Length
- Weight/metre
- Roundness
- Surface finish
- Colour consistency
- Socket dimensions
- Bell formation
- Printing quality
- Dimensional tolerances
Immediately inform the Quality Department and Production Manager in case of any deviation.
The operator must be able to identify common CPVC extrusion defects, including:
- Uneven wall thickness
- Ovality
- Surface roughness
- Melt fracture
- Sharkskin
- Die lines
- Black spots
- Discolouration
- Burning
- Poor fusion
- Pipe sagging
- Dimensional variation
- Vacuum calibration defects
- Belling/socket defects
4. Troubleshooting Responsibilities
The candidate should have practical knowledge of troubleshooting:
- Unstable extrusion output
- Pressure fluctuations
- Motor load variation
- Temperature fluctuations
- Feeding problems
- Screw torque issues
- Material bridging
- Die blockage
- Die contamination
- Pipe thickness variation
- Pipe ovality
- Poor surface finish
- Vacuum instability
- Cooling problems
- Haul-off slippage
- Cutter length variation
- Socketing/belling defects
The operator should coordinate with the Maintenance Team for electrical, mechanical and instrumentation-related issues.
5. Raw Material & Compounding Knowledge
The candidate should have practical knowledge of CPVC extrusion raw materials and formulations.
Experience with:
- CPVC resin
- Heat stabilizers
- Lubricants
- Processing aids
- Impact modifiers
- Pigments/colour masterbatch
- Other CPVC formulation additives
The operator should understand the impact of incorrect dosing or variation in raw material quality on:
- Fusion
- Melt strength
- Output
- Surface finish
- Colour
- VST performance
- Hydrostatic pressure performance
- Reversion
- Impact strength
Experience working with Indian CPVC resin grades and stabilizer/lubricant systems will be preferred.
6. Testing & Quality Awareness
The candidate should have knowledge of production-related quality testing and should understand the importance of:
- Hydrostatic pressure testing
- VST / Vicat Softening Temperature
- Reversion test
- Impact test
- Flattening test
- Dimensional testing
- Weight/metre verification
- Visual inspection
The operator must work closely with the QC/QA Department to ensure production parameters consistently achieve required product specifications.
7. Die & Tooling Knowledge
Candidate should have basic-to-advanced knowledge of:
- CPVC die head operation
- Die alignment
- Die cleaning
- Die setting
- Die gap adjustment
- Mandrel alignment
- Calibration sleeve
- Vacuum sizing
- Changeover procedures
Ability to independently perform die changeover and size changeover will be an added advantage.
8. Preventive Maintenance
- Perform daily machine inspection.
- Check lubrication points.
- Monitor abnormal sounds and vibrations.
- Check heater bands and thermocouples.
- Check temperature controllers.
- Check vacuum pump performance.
- Check cooling-water circulation.
- Monitor gearbox and motor conditions.
- Maintain cleanliness of extruder and surrounding area.
- Report maintenance requirements immediately.
- Follow preventive maintenance schedules.
9. Shift Management
- Properly hand over machine status to the next shift operator.
- Record production output and rejection.
- Record machine downtime.
- Mention reasons for stoppages.
- Maintain shift-wise parameter sheets.
- Ensure raw material availability before production.
- Coordinate with:
- Production Planning
- Quality Control
- Maintenance
- Stores
- Packing Department
10. Safety Responsibilities
- Follow all plant safety SOPs.
- Use mandatory PPE.
- Follow safe operating procedures for high-temperature zones.
- Maintain safe distance from rotating components.
- Follow Lockout/Tagout procedures during maintenance.
- Ensure no unauthorized person operates the extrusion line.
- Immediately report unsafe conditions.
11. Required SkillsMandatory Skills
- CPVC pipe extrusion experience
- Theyson/Conical Twin-Screw Extruder operation
- CPVC processing parameter knowledge
- Die setting knowledge
- Vacuum calibration knowledge
- Cooling system knowledge
- Haul-off and cutter operation
- Production troubleshooting
- Quality parameter control
- Shift production reporting
Preferred Skills
- Experience with high-output CPVC pipe extrusion
- Experience with 20 mm–160 mm CPVC pipe production
- Experience with multiple CPVC pressure classes
- Experience in ASTM/IS standard-based production
- Experience with automated extrusion lines
- Experience in VST and reversion-related process optimization
- Knowledge of SAP/ERP production reporting
12. Key Performance Indicators (KPIs)
The employee will be evaluated on:
KPITargetProduction Achievement≥ 95% of planned productionMachine UtilizationMaximum possible uptimeMaterial WastageMinimum possibleRejection RateWithin approved plant targetQuality ComplaintsZero avoidable complaintsProcess StabilityConsistent parametersDowntimeMinimum controllable downtimeChangeover TimeWithin standard timeSafety Compliance100%Production Reporting100% accurate and timely13. Educational Qualification
ITI / Diploma in Mechanical, Plastic Technology, Polymer Technology or related field preferred.
Candidates with strong practical CPVC extrusion experience may also be considered.
14. Experience RequirementSenior Operator
5–8 years experience in CPVC pipe extrusion.
Machine Operator
3–5 years experience in CPVC pipe extrusion.
Candidates with experience specifically on Theyson/Conical Twin-Screw CPVC extrusion lines will be given priority.
15. Personal Attributes
The candidate should be:
- Technically strong
- Production-oriented
- Quality-conscious
- Disciplined
- Safety-conscious
- Able to work in shifts
- Good at troubleshooting
- Capable of working under production pressure
- Team-oriented
- Willing to take ownership of machine performance
16. Compensation
Salary: As per experience and technical capability.
Additional benefits may include:
- Performance-based incentives
- Attendance bonus
- Overtime as per company policy
- Accommodation/transport support, if applicable
- Food/canteen facility
- PF & ESIC as applicable
- Career growth opportunities
17. Ideal Candidate Profile
We are looking for a hands-on CPVC extrusion professional who can independently take responsibility for a CPVC Theyson extrusion line and deliver stable production with consistent quality.
The ideal candidate should not be only a machine operator. He should be capable of understanding the complete CPVC extrusion process, optimizing machine parameters, troubleshooting process problems, controlling wastage and coordinating with QC and Maintenance teams.
Candidates who have directly operated CPVC Theyson/Conical Twin-Screw extrusion lines will be strongly preferred.
Application
Interested candidates may share their CV mentioning:
- Total experience
- CPVC extrusion experience
- Theyson machine experience
- Machine model
- Pipe sizes handled
- Maximum output achieved
- Current CTC
- Expected CTC
- Notice period
- Current location
Pay: ₹15,000.00 - ₹45,000.00 per month
Work Location: In person
