Senior APC Engineer - Process Optimisation Applications (PXP)

Job Summary

Senior APC Engineer - Process Optimisation Applications (PXP)

As a Senior APC Engineer, you will carry this legacy forward by applying advanced process control, analytics, and AI/ML technologies to cement and mining operations worldwide. At Fuller, APC engineering is not just about control algorithms - it is about understanding the process, earning customer trust, and delivering performance that lasts.

You will be part of Fullers Process Optimisation Team, working with the ECS/ProcessExpert APC toolbox and advanced control techniques such as MPC and AI/ML. Your role focuses on delivering APC and soft-sensor solutions that stabilise plant operations, improve throughput, and reduce energy and fuel consumption.

This is a hands-on technical role with responsibility across the full APC project lifecycle - from process analysis and model development to commissioning, optimisation, and long-term performance support.

Responsibilities

• Perform process and data analysis using historical and real-time data from cement and minerals plants to identify optimisation opportunities.
• Design, develop, test, and deploy predictive models and soft sensors using linear and non-linear AI/ML algorithms.
• Implement, validate, and maintain real-time APC applications using MPC, AI/ML, fuzzy logic, and PID control strategies.
• Estimate and quantify process improvement benefits using data analytics, supporting performance guarantees and technical proposals.
• Adapt, tune, and retrain models and controllers to ensure sustained performance and operational stability.
• Define and implement process control strategies, including configuration and commissioning of APC solutions.
• Fine-tune MPC, fuzzy, and PID controllers to achieve guaranteed performance targets related to productivity, energy efficiency, and stability.
• Support system integration activities, including hardware selection, software installation, and connectivity with PLCs, DCS, and historians.
• Collaborate with project managers and customer teams to ensure APC projects are delivered on schedule and to specification.
• Provide training and technical mentoring to APC engineers on data analytics and AI/ML applications within the ECS/ProcessExpert platform.
• Evaluate emerging developments in advanced analytics and non-linear modelling to continuously improve APC applications.
• Contribute across the broader APC lifecycle, including sales support, product development, feature testing, and service support as required.

Qualifications

• Strong hands-on experience in Advanced Process Control, Data Analytics, Machine Learning, and AI applied to industrial processes.
• Proven experience in data mining, statistical modelling, model deployment, and real-time implementation.
• Background in process manufacturing industries; cement and minerals process knowledge is a strong advantage.
• Solid understanding of process optimisation, control strategy development, and benefit analysis.
• Experience with industrial data connectivity and historians, including SQL, MQTT, PLCs, DCS, and modern data platforms.
• Familiarity with AI/ML and data analytics tools commonly used in process industries, including: Python, Pandas, NumPy, Scikit-Learn, TensorFlow, Matplotlib, Seaborn, Databricks
• Willingness to travel (40-60%) within India and internationally for commissioning, pilot testing, customer engagement, and training.

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