Senior Filling & Packaging Technician (Tetra Pak A3/Flex)

About the role

Senior technician responsible for the technical performance, uptime and food safety of the Tetra Pak A3/Flex filling line at Farm Fresh Enstek. The role covers both the A3/Flex filling machine and Tetra Pak downstream equipment (Helix straw applicator, CAP30F, CBP cardboard packer), ensuring stable aseptic operation, fast changeover and strict GMP/HACCP/EHS compliance.

Key responsibilities

• Operate, monitor and maintain the Tetra Pak A3/Flex filling machine ensuring stable aseptic conditions and package integrity.
• Operate and maintain Tetra Pak downstream equipment: Helix straw applicator, CAP30F cap applicator and CBP cardboard packer; ensure tight integration with the FM.
• Lead sterilisation, production, intermediate cleaning and CIP/SIP cycles of the line as per Tetra Pak / Farm Fresh SOPs.
• Execute fast, accurate product, packaging-material and format changeovers; minimise changeover time and packaging-material waste.
• Diagnose and resolve mechanical, electrical, pneumatic and process issues on FM and DE; perform first-line repairs and escalate complex failures.
• Plan and execute preventive maintenance, daily/weekly/monthly service kits and overhauls following Tetra Pak service-management recommendations.
• Monitor and drive key indicators: OEE, package integrity (TAA, drop test, seal test), MTBF, MTTR, waste, downtime reasons.
• Maintain accurate documentation: shift logs, batch records, aseptic challenge tests, CIP/SIP records, package-integrity test results, spare-parts consumption.
• Coach junior technicians and operators on safe operation, aseptic discipline and basic troubleshooting on FM, Helix, CAP30F and CBP.
• Coordinate with QA/QC on package integrity tests, microbiological results, deviations and CAPA.

About you

• Diploma / Degree in Mechanical, Electrical, Mechatronics, Food Engineering or related discipline.
• Minimum 5-8 years of hands-on experience on Tetra Pak A3/Flex (or equivalent TBA/A1/A3) filling machines in a dairy, beverage or liquid food environment.
• Demonstrated experience with Tetra Pak downstream equipment: Helix straw applicator, CAP30F, CBP cardboard packer.
• Strong working knowledge of aseptic processing, sterilisation cycles, CIP/SIP and aseptic-zone integrity.
• Solid mechanical, electrical and pneumatic troubleshooting skills; able to read P&IDs, electrical schematics and Tetra Pak OEM manuals.
• Exposure to PLC / HMI fault-finding (Siemens / Allen-Bradley) and basic instrumentation.
• Knowledge of GMP, HACCP, ISO 22000, HALAL and EHS standards.
• Strong leadership, mentoring and problem-solving skills; able to lead a shift team.
• Willing to work on rotating shift, weekends and public holidays.
• Proficient in Bahasa Malaysia and English; competent in MS Office.