Plant Head – Copper CCR Plant (Greenfield Project)
Job Description: We are looking for a highly experienced, execution-driven Plant Head to lead the setup and operations of our new Copper CCR (Continuous Casting and Rolling) Plant at Cypress Industries. This is a strategic Greenfield project that will produce high-quality copper wire rods. If you have a proven track record of erecting CCR lines and mastering the continuous casting and rolling process, this is a career-defining opportunity to build and run a critical facility.
Role Overview As the Plant Head, you will take total ownership of this Greenfield CCR project from day one. You will direct the site layout, machinery selection, and the erection and commissioning of the melting/holding furnaces, casting machines, rolling mills, and coilers. Once operational, your mandate is to transition into full P&L leadership. You will ensure the seamless synchronization of the melting, casting, and hot-rolling processes to produce high-conductivity copper wire rods with flawless surface quality, maximizing yield while strictly controlling energy consumption and refractory life.
Key Responsibilities
- Greenfield CCR Execution: Direct the end-to-end erection and commissioning of the complete CCR line, including shaft/melting furnaces, holding furnaces, casting wheels/tundish, rolling mill stands, and coiling systems.
- Process Synchronization: Establish exacting Standard Operating Procedures (SOPs) to perfectly synchronize casting wheel speed with the rolling mill to prevent cobbles, tension issues, or rod breakages.
- Metallurgy & Rod Quality: Take ownership of the final copper rod quality (e.g., 8mm ETP rod). Strictly control the oxygen content, impurity levels, and grain structure to ensure the rod is suitable for fine wire drawing.
- Emulsion & Systems Management: Oversee the critical cooling, lubrication, and emulsion systems for the rolling mill to ensure superior rod surface finish and maximize the life of the rolling rolls.
- Refractory & Maintenance: Implement aggressive predictive maintenance schedules for furnace refractories, casting belts/wheels, and rolling mill gearboxes to minimize unplanned downtime.
- Statutory & Emission Control: Ensure flawless operation of exhaust systems and scrubbers, maintaining strict compliance with local Pollution Control Board (PCB) regulations.
- Floor-First Leadership: Hire, train, and mentor the core CCR team, including furnace operators, casting operators, rolling mill technicians, and maintenance engineers.
Required Experience
- 8+ years of hardcore experience in copper metallurgy, with a heavy focus on CCR (Continuous Casting and Rolling) operations.
- 3–5+ years functioning as a Plant Head, Factory Manager, or Project Head.
- Greenfield Experience Mandatory: You must have successfully led the erection and commissioning of at least one CCR line (e.g., Properzi, Southwire, or similar technology) from scratch.
- Skills & Attributes
- Mechanical & Metallurgical Master: You understand that a CCR line is a delicate balance. You know how to troubleshoot complex mechanical issues in the rolling mill just as well as you understand furnace chemistry.
- Builder & Problem Solver: You know how to navigate the bottlenecks of a Greenfield setup (delayed contractors, machinery alignment issues, or utility constraints) without losing momentum.
- Floor-First Mindset: You do not manage from an air-conditioned cabin. You are present on the platform, inspecting the casting wheel, checking the emulsion, and guiding your operators.
Knowledge Requirements
- Expert knowledge of CCR technologies, including continuous casting dynamics, hot-rolling mechanics, and in-line quenching systems.
- Deep understanding of copper scrap/cathode melting, fluxing, and the chemistry required to produce high-conductivity copper rods.
- Comprehensive knowledge of industrial safety gear, molten metal hazard management, and lockout/tagout (LOTO) procedures.
What We Are Looking For We are looking for a true CCR expert. We need a leader who can look at an empty site, visualize a highly efficient, synchronized continuous casting and rolling plant, and possesses the technical grit to actually build it, fire it up, and produce world-class copper rods.
Application Question(s):
- Have you worked with a CCR copper furnace? If so what size of daily production?
- Please detail your Greenfield experience. What specific CCR technologies (e.g., Properzi, SCR) and capacities have you successfully erected and commissioned?
- How do you measure copper quality?
- Do you know what an induction furnace is? Have you worked/handled one befoere? if yes, describe your experience.
- Have you worked with copper scrap before? If yes, how?
- In a CCR line, what is your specific approach to troubleshooting surface defects on the final copper rod and managing the rolling mill emulsion system?
- What is your current CTC / in-hand?
- What is your expected CTC/ in hand?
- What is your notice period, and up to how many days can it be negotiated?
- Are you comfortable travelling/relocating to Vasna Chancharwadi, Ahmedabad, and working 6 days a week?
Work Location: In person – Vasna Chancharwadi, Ahmedabad, Gujarat
Pay: ₹800,000.00 - ₹2,000,000.00 per year
Benefits:
- Paid sick time
- Provident Fund
Application Question(s):
- Have you worked with a CCR copper furnace? If so what size of daily production?
- Please detail your Greenfield experience. What specific CCR technologies (e.g., Properzi, SCR) and capacities have you successfully erected and commissioned?
- How do you measure copper quality?
- Do you know what an induction furnace is? Have you worked/handled one before? if yes, describe your experience.
- Have you worked with copper scrap before? If yes, how?
- In a CCR line, what is your specific approach to troubleshooting surface defects on the final copper rod and managing the rolling mill emulsion system?
- What is your current CTC / in-hand?
- What is your expected CTC/ in hand?
- What is your notice period, and up to how many days can it be negotiated?
- Are you comfortable travelling/relocating to Vasna Chancharwadi, Ahmedabad, and working 6 days a week?
Work Location: In person
