Sr. Executive - Maintenance

1. Position Details ParticularDetails Designation Senior Refrigeration Technician Department Engineering / Plant Maintenance Reporting To Maintenance Supervisor / Assistant Manager / Maintenance Manager Location Bakery Manufacturing Plant Experience 5–8 Years Relevant Experience Employment Type Full Time Shift Rotational Shift
2. Job Purpose To ensure the safe, reliable and efficient operation of all refrigeration systems supporting bakery production, raw-material storage and finished-goods storage. The Senior Refrigeration Technician will be responsible for preventive maintenance, breakdown troubleshooting, temperature control, refrigeration performance, compressor maintenance, refrigerant management and minimizing refrigeration-related downtime. 3.

Key Responsibilities

A. Refrigeration System Maintenance Carry out operation, preventive maintenance and breakdown maintenance of: Cold Rooms Blast Freezers Deep Freezers Chillers Refrigerated Storage Areas Refrigeration Compressors Condensers Evaporators Expansion Valves Solenoid Valves Receiver Tanks Filter Driers Accumulators Refrigerant Piping Temperature Controllers Pressure Controls Defrost Systems Refrigeration Control Panels Ensure all refrigeration equipment operates within the recommended operating parameters. 4. Compressor Maintenance Hands-on experience in maintenance and troubleshooting of: Reciprocating Compressors Scroll Compressors Screw Compressors Semi-Hermetic Compressors Hermetic Compressors Responsibilities include: Monitor suction and discharge pressure. Check compressor oil level and condition. Check compressor running current. Monitor discharge temperature. Check abnormal noise and vibration. Check compressor loading/unloading. Troubleshoot high-pressure and low-pressure trips. Check overload and safety cut-outs. Identify compressor performance deterioration. Coordinate compressor replacement/overhauling with OEM when required. 5. Cold Room Maintenance Ensure required cold-room temperature is maintained. Monitor temperature continuously and record readings. Inspect evaporator coils and condenser condition. Clean evaporator and condenser coils. Check evaporator fans and motors. Check cold-room door gaskets and hinges. Inspect door heaters and safety release mechanisms. Check drain lines and drain heaters. Ensure proper defrost operation. Check insulation and identify possible heat ingress. Troubleshoot abnormal temperature rise. Investigate repeated temperature deviations. 6. Blast Freezer Maintenance Maintain blast freezer refrigeration systems. Monitor freezing temperature and pull-down time. Check compressor, condenser and evaporator performance. Monitor suction/discharge pressure. Check refrigerant level and leakage. Check evaporator fan operation. Inspect defrost system. Check door sealing and insulation. Identify reasons for slow freezing or inadequate cooling. Maintain equipment performance records. 7. Chiller Maintenance Operate and maintain refrigeration/chiller systems. Monitor chilled-water supply and return temperatures. Check compressor loading. Monitor refrigerant pressure. Check condenser and evaporator performance. Check chilled-water pumps. Inspect valves, strainers and piping. Check water flow and differential pressure. Maintain daily chiller log sheets. Coordinate with OEM for major breakdowns and annual servicing. 8. Refrigerant Management Carry out refrigerant charging and recovery as per approved procedures. Conduct refrigerant leak testing. Use appropriate leak-detection equipment. Carry out system evacuation/vacuuming before charging. Maintain proper refrigerant charge. Maintain records of refrigerant charging and recovery. Ensure refrigerant cylinders are stored safely. Minimize refrigerant leakage and unnecessary refrigerant consumption. Follow applicable environmental and safety requirements. 9. Preventive Maintenance Execute daily, weekly, monthly and annual PM activities. Typical PM activities: Compressor inspection Oil level inspection Suction/discharge pressure checking Condenser cleaning Evaporator cleaning Fan motor inspection Belt inspection Refrigerant leakage inspection Electrical terminal tightening Pressure switch inspection Temperature sensor checking Expansion valve inspection Defrost system inspection Drain line cleaning Insulation inspection Door gasket inspection Vibration/noise inspection Refrigeration panel inspection Ensure PM compliance ≥95% . 10. Breakdown Maintenance Attend refrigeration breakdown calls immediately. Diagnose faults systematically. Minimize refrigeration downtime. Troubleshoot: High-pressure trip Low-pressure trip Compressor overload Compressor failure Refrigerant leakage Low cooling capacity Evaporator icing Condenser choking Fan failure Expansion valve malfunction Solenoid valve failure Sensor failure Defrost failure Temperature controller failure Restore equipment safely and quickly. Conduct RCA for major/repeated breakdowns. Escalate critical failures to the Maintenance Manager/OEM. 11. Temperature Monitoring Monitor and maintain temperature of: Raw Material Cold Rooms Finished Goods Cold Rooms Dairy / Cream Storage Frozen Product Storage Blast Freezers Refrigerated Production Areas Chilled Water Systems Maintain temperature logs. Immediately report abnormal temperature deviations. Coordinate with QA and Production during critical temperature deviations. Support temperature mapping and validation activities where required. 12. Electrical & Controls Troubleshooting Should have working knowledge of: Contactors Relays MCB/MCCB Overload Relays VFDs Temperature Controllers Thermostats Pressure Switches Solenoid Valves Sensors Timers Control Panels PLC/BMS interface Use multimeter and clamp meter for basic electrical troubleshooting. 13. Energy Efficiency Monitor refrigeration energy consumption. Identify abnormal power consumption. Optimize compressor operation. Avoid unnecessary compressor running. Maintain clean condensers and evaporators. Ensure correct refrigerant charge. Monitor suction/discharge pressure. Ensure proper insulation. Identify heat ingress in cold rooms. Support plant energy-saving initiatives. 14. Spare Parts Management Identify and maintain critical refrigeration spares such as: Compressor Compressor Oil Expansion Valve Solenoid Valve Filter Drier Pressure Switch Temperature Sensor Thermostat Fan Motor Evaporator Fan Condenser Fan Contactors Overload Relays Refrigerant Copper Fittings Insulation Material Belts and Bearings Inform the supervisor regarding critical spare requirements before stock-out. 15. Safety Responsibilities Follow all plant safety procedures. Follow LOTO (Lockout/Tagout) before maintenance. Use appropriate PPE. Follow safe refrigerant-handling procedures. Ensure pressure is safely released before opening refrigeration circuits. Follow electrical safety procedures. Follow safe working-at-height practices. Never bypass safety devices without authorization. Ensure proper housekeeping around refrigeration equipment. Report unsafe conditions immediately. 16. Vendor & OEM Coordination Coordinate with refrigeration OEMs and AMC vendors. Supervise vendor maintenance activities. Verify technical work completed by vendors. Check service reports. Support compressor replacement and major refrigeration repairs. Coordinate annual preventive maintenance. Assist in commissioning of new refrigeration equipment. 17. Production & QA Coordination Coordinate with Production for planned refrigeration maintenance. Minimize impact on production and storage operations. Inform Production about expected downtime. Coordinate with QA during temperature deviations. Support food-safety and quality audits. Ensure proper temperature records are maintained. Immediately escalate any condition that may affect stored food products. 18. Documentation & Reporting Maintain: Daily refrigeration log Cold-room temperature records Blast-freezer temperature records Chiller log sheets PM checklists Breakdown reports Equipment history Compressor running-hour records Refrigerant charging records Refrigerant leakage records Spare consumption records Vendor service reports RCA reports Ensure shift handover includes all pending refrigeration issues. 19. Key Performance Indicators (KPIs) KPITarget / Focus Refrigeration PM Compliance ≥95% Cold Room Availability ≥98% Blast Freezer Availability ≥98% Chiller Availability ≥98% Temperature Compliance ≥99% Breakdown Response Time Minimum possible MTTR Continuous reduction MTBF Continuous improvement Repeat Breakdown Continuous reduction Refrigerant Leakage Minimum Energy Consumption Continuous reduction Safety Compliance 100% Documentation Compliance 100% 20. Technical Skills Required Strong hands-on knowledge of industrial refrigeration. Good understanding of refrigeration cycles. Strong compressor troubleshooting skills. Knowledge of refrigerant charging/recovery. Knowledge of vacuuming and leak testing. Ability to troubleshoot high/low pressure issues. Knowledge of condenser and evaporator systems. Knowledge of expansion valves and solenoid valves. Knowledge of defrost systems. Knowledge of cold-room systems. Knowledge of blast freezers. Knowledge of chillers. Basic electrical troubleshooting skills. Ability to read refrigeration and electrical drawings. Knowledge of HVAC controls/BMS will be an advantage. 21. Educational Qualification Minimum Qualification: ITI – Refrigeration & Air Conditioning (RAC) OR Diploma in Refrigeration & Air Conditioning / Mechanical Engineering. ITI Electrical/Mechanical candidates with strong refrigeration experience may also be considered. 22. Experience 5–8 years of relevant experience in industrial refrigeration. Experience in bakery, food manufacturing, FMCG, QSR, central kitchen, cold-chain or food-processing plants preferred. Hands-on experience with cold rooms, blast freezers, chillers and industrial compressors is required. Experience handling refrigeration breakdowns independently is preferred. 23. Behavioural Competencies Strong troubleshooting and analytical skills. Good communication and coordination. Strong ownership and accountability. Ability to work under production pressure. Safety-conscious approach. Team player with ability to work independently. Good documentation skills. Willingness to work in rotational shifts. Ability to respond to emergency breakdowns. 24. Ideal Candidate Profile The ideal candidate should be a hands-on Senior Refrigeration Technician capable of independently maintaining and troubleshooting industrial refrigeration systems, cold rooms, blast freezers, chillers, compressors, condensers, evaporators and refrigeration controls . The candidate should have a strong focus on temperature control, equipment reliability, minimum downtime, energy efficiency, food-safety requirements and safe refrigeration practices .