Production Manager-Thermoforming, Shirwal, Pune (CTC 10-15L per annum)

Company Description

Nyplia is a global materials innovation company dedicated to replacing conventional plastics with next-generation bioplastics and sustainable materials. Through cutting-edge research and scalable manufacturing, Nyplia develops high-performance, compostable, and biodegradable alternatives that meet the demands of modern industries— without compromising quality or functionality. Founded on the mission to accelerate the transition toward carbon-neutral manufacturing systems, Nyplia helps industries reduce their environmental footprint and build circular supply chains. Its product portfolio spans compostable packaging films, food containers, medical sheets, and bioplastic granulates; all designed for large scale industrial applications.

Role Overview

We are setting up a greenfield thermoforming manufacturing facility at Shirwal for manufacturing food-grade rigid packaging products such as 3CP–8CP meal trays, sauce/dip containers, party glasses, punnets, hinged containers, sweet/bakery boxes and other food packaging products in PP and PET. We are looking for a hands-on Production Manager with strong experience in sheet extrusion + thermoforming who can participate in plant commissioning and subsequently take ownership of production operations.

Key Responsibilities

• Lead commissioning and production ramp-up of PP/PET sheet extrusion and thermoforming lines.

• Manage complete process from granules → sheet extrusion → thermoforming → trimming → regrind/recycling → finished product.

• Set and optimise extrusion parameters including PET drying, temperature profiles, sheet gauge, roll temperatures and regrind ratios.

• Optimise thermoforming parameters including heating, vacuum/pressure, plug assist, mould cooling, cycle time and trimming.

• Conduct new mould/product trials and establish optimum sheet thickness, product weight and process parameters.

• Achieve production targets for output, OEE, cycle time, machine utilisation and pieces/kg.

• Drive material yield improvement, lightweighting, scrap reduction and regrind optimisation.

• Troubleshoot sheet extrusion, thermoforming, mould and product-quality issues.

• Establish SOPs, process sheets, production systems and preventive-maintenance practices.

Ensure GMP, hygiene, traceability and food-contact packaging compliance.

• Recruit, train and manage production supervisors, operators and technicians.

• Coordinate with machine/mould suppliers, Quality, Maintenance, Purchase and Product Development teams.

Strongly Preferred

• Experience with both PP and PET.

• Previous greenfield plant / new-line commissioning experience.

• Experience in food-contact packaging manufacturing.

• CIPET background.

• Demonstrated experience in lightweighting, scrap reduction, cycle-time improvement and OEE improvement. 

Key KPIs

• Production output | OEE | Machine utilisation | Cycle time | Pieces/kg | Product weight | Extrusion yield | Scrap/rejection % | Regrind utilisation | Customer rejection | Downtime
• Critical Screening Requirement
• Candidates should have hands-on exposure to sheet extrusion as well as thermoforming. Candidates whose experience is limited to operating thermoforming machines using externally purchased ready sheet would not be preferred.