Shift Sampler (Laboratory) - Illovo Sugar Limited - Kwazulu Natal, South Africa
(2001-03 - 2003-03)
- Collect samples of sugar and various factory products, and convey them to the laboratory.
- Adhere strictly to procedures regarding rinsing, cleaning and conveying of sample containers.
- Weigh, dilute and dissolve samples as per procedure.
- Clarify and filter diluted sample as per procedure.
- Report to the supervisor any sampling points that are non-functional.
- Report any out of spec analysis to backend supervisor
- Ensure housekeeping standards are maintained
- Keep laboratory tidy at all times.
- Undertake non-routine work related to the job as need arises.
- Undertake off crop duties as per off crop plan.
Operator Centrifugal (Centrifugal Station) - Illovo Sugar Limited - Kwazulu Natal, South Africa
(2003-03 - 2004-06)
- Operates A-centrifugals as per operating procedures.
- Elects to run the minimum / maximum number of machines to maintain desired massecuite levels in the crystallisers.
- Adjust PLC's to ensure that centrifugals produce A sugar to specification.
- Conduct regular checks to ensure that all pumps, conveyors and sugar handling equipment are operational.
- Once per shift stops, cleans and inspect each centrifugal to ensure that screens / sprays are intact.
- Maintains acceptable level of plant cleanliness.
- Reports any defective machinery to the backend supervisor.
- Conducts checks twice per shift to ensure that cooling water and massecuite dilution take place accordingly.
- Undertake non-routine work related to the job as need arises.
- Undertakes off crop duties as per off crop plan.
Plant Evaporator Operator (Clarification) - Illovo Sugar Limited - Kwazulu Natal, South Africa
(2004-06 - 2006-08)
- Operate evaporator station.
- Operate juice heater station.
- Ensure the condensate to boilers is adequate and of required quality.
- Maintain acceptable standard of plant cleanliness.
- Takes 4 hourly composite syrup samples to the laboratory.
- Takes 2 hourly clear juice samples to the laboratory.
- Ensure juice heater cleaning is taking place as per schedule.
- Comply with Occupational Health and Safety Act and ISO requirements at all times.
- Look after liming of juice and dosing of enzyme.
- Undertake non-routine work related to the job as need arises.
- Undertakes off crop duties as per off crop plan.
- Involved in supervision of labour on stop days, pressure testing of evaporators and efficient changing of metex screens
Trainee Pan Boiler (Back End) - Illovo Sugar Limited - Kwazulu Natal, South Africa
(2006-09 - 2008-02)
Followed the Criterion Reference Index (CRI) Programme for A, B and C Pan boiling and completed the respective tests for each module as per the two year programme. Obtained practical, on the job training by working closely with Pan Boilers on shift as per the two year programme. Worked in other areas of the mill from time to time as part of development.
Boiled pans under pan boilers' supervision to specific operational procedures and compiles pan cycles. Operated all equipment associated with pan boiling, under close supervision. As a trainee, I was used anywhere in the plant as per requirement, and was required to go the extra mile – working late, public holidays, special holidays, weekends, etc.
- Inspection of pans on stop days or as required.
- Operate vacuum pumps.
- Operated all types of valves (eg. Saundos, knife gate, etc.).
- Dose chemicals.
- Steam out pans.
- Stop and start pumps, as per procedure.
- Monitor massecuite grain size.
- Pressure testing of pans (Stop days or as required)
- Check crystallisers.
- Adhered to all safety, health, and environment and quality requirements.
- Attended various external courses as planned on the two year training programme.
- Underwent regular performance assessments, as per 2 year programme.
- Relieved pan boilers as deemed fit by Process.
- Off crop duties
- Assisted in maintenance of the plant as per foremans' instruction, the following was covered: Stripping of the valves, sight glasses, pipes, etc., Pan inspections, Any other job as per foremans' instruction.
Process Trainee - Illovo Sugar Limited - Kwazulu Natal, South Africa
(2008-03 - 2009-02)
Reported to Assistant Process Manager. Underwent a two year developmental programme.
- Was responsible for supervision of staff, conflict management, data collection.
- Implemented and monitored new projects.
- Updated and implemented new work instructions and training manuals.
- Perform plant trials utilizing new chemicals.
Pan Floor Supervisor (Pan Floor) - Illovo Sugar Limited - Kwazulu Natal, South Africa
(2009-03 - 2010-03)
Supervised pan boiler (B5) and operator raw house (Pan Hand B1) on shift.
- Ensured good quality massecuites were produced by checking on the pan temperature, super-saturation and size of crystals, and optimizing operations across pans and crystallisers.
- Conducted practical training for Trainee Pan Boilers as per procedure and in conjunction with the Process Foreman.
- Ensured details of all pan operations and stocks were recorded correctly in the pan logbook, stock sheets and shift log sheet.
- Reported to the shift foreman on labour, production and quality issues.
- Maintained good housekeeping and safety standards.
- Responsible for the process functions of all automatic controls (instruments) on the pan floor.
- Controlled auto pan boiling using the desired instrument.
- Optimised process performance by manipulating pan boiling techniques to maximise exhaustion on A, B and C massecuites.
- Implemented and maintained the requirements of the NOSA and SABS ISO 9001:2000 Quality Management System.
- Undertook non-routine work related to the job as need arose.
- Undertook off crop duties as per off crop plan.
Shift Foreman (Operations) - Illovo Sugar Limited - Kwazulu Natal, South Africa
(2010-04 - 2017-08)
Ensured that all manufacturing processes (i.e., Back End) operated within the laid down standards by checking control data and analyses of products produced by the laboratory (Hourly). Emphasis was on proactively monitoring parameters and responding with a follow up action. Also ensured mates follow up and close the loop, e.g. A m/c brix low on a certain hour.
- Liaised with Sugar Supervisor to ensure that the raw juice is processed into syrup at the required rate and standard with the lowest possible cost (Ongoing).
- Ensured all manufacturing processes operated within laid down standards, including achievements of targets for Boiling House Recoveries, Overall Recovery and Final Molasses Purity (Ongoing).
- Boiling House Recovery was maximised by: Minimising sucrose loss in filter cake, Minimising sucrose loss in filtrate, Minimising sucrose loss across the clarifier, Minimising sucrose loss through entrainment in evaporators, Minimising sucrose loss during evaporator liquidation, Minimising sucrose loss through control of spillage, Minimising chemical destruction of sucrose and reducing sugars.
- Ensured that all-final molasses is disposed of as per instruction from Pure Cane Molasses at the lowest possible cost per ton.
- Minimise sucrose loss in molasses (Ongoing).
- Raw sugar was produced from the required rate of syrup at the specified SASA quality standards with the lowest possible cost.
- Maintenance and cleaning operation on scheduled stop e.g. evaporator cleaning as well as the process maintenance during the off crop period is properly planned, supervised and controlled (Ongoing).
- Made sure works orders were in the system and these are carefully monitored and closed out.
- Advised on starting up, shutting down / boiling off to accommodate schedule stop, no cane or breakdowns in accordance with laid down procedures and standing instructions (As necessary).
- Stop day shut-down was monitored and carefully controlled according to stop day meeting targets.
- Ensured catchment sumps for effluent are functioning properly and that no bagasse or sugar juice finds its way into effluent plant (Ongoing).
- A proactive approach was required on the lab effluent sample and an investigation on high readings.
- Liaised with Cane Testing Services regarding mixed juice sampling.
- Scale bypassing strictly controlled and the necessary documentation
