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The Technical Manager is accountable for the technical performance, process optimisation, and automation integrity of the integrated Berrima Kiln and Marulan Lime Kiln, its associated grinding stations in Geelong, Maldon and Berrima and will provide process support to the Sand Plant in Marulan. The role leads a multi-disciplinary technical team of four Process Engineers and one Automation Engineer to drive production efficiency, product quality, energy performance and reliability across all sites. The role acts as the primary technical authority bridging process,
quality, reliability and control systems, translating plant data into decisions that lift output, reduce cost and protect asset integrity. This role will be based at Berrima in NSW, Australia but involve periodic travel to the operational sites.
Your day will involve:
Process Engineering & Plant Performance
- Monitor and analyse kiln, raw mill, cement mill and grinding station performance data daily; identify and resolve process bottlenecks.
- Set, review and continuously refine process control targets (e.g. specific power, heat consumption, throughput, false air, cyclone efficiency) for the plant and both grinding stations.
- Lead process trials (alternative fuels, raw materials, cementitious additions, grinding aids) and evaluate results against cost, quality and emissions objectives.
- Oversee mass and energy balance reviews, and support annual budgeting and specific energy consumption improvement plans.
Quality Management
- Ensure clinker and cement quality parameters remain within specification across the plant and both grinding stations, coordinating closely with Quality/Laboratory teams.
- Investigate and close out quality non-conformances, customer complaints and product deviations, applying root-cause methodologies.
- Support new product development and cement blend optimisation (e.g. blended cements, SCMs, low-carbon formulations).
Automation, Control Systems & Digitalisation
- Direct the Automation Engineer's work program across DCS/PLC platforms, expert/advanced process control (APC) systems and instrumentation at all three sites.
- Ensure control system logic, interlocks and alarm management are fit-for-purpose, well documented and consistently applied across sites.
- Champion the deployment and tuning of advanced process control, online analysers and soft sensors to reduce variability and manual intervention.
- Ensure cyber-security, backup, change-management and version-control practices are followed for all control system and automation changes.
Reliability, Maintenance Interface & Continuous Improvement
- Partner with Maintenance and Reliability teams on process-related failure investigations, condition monitoring trends and equipment performance reviews.
- Lead or support structured problem-solving (RCA, 5-Why, Six Sigma/Lean) for chronic process and quality issues across the three sites.
- Contribute technical input into shutdown planning, scope development and post-shutdown performance verification.
Safety, Health, Environment & Compliance
- Ensure all process trials, control system changes and technical interventions follow site safety systems, management-of-change and permit-to-work processes.
- Support environmental compliance related to process operation, including emissions monitoring, dust management and energy/carbon reporting.
Leadership & People Management
- Lead, coach and performance-manage 4 Process Engineers and 1 Automation Engineer, allocating workload appropriately across the plant and two grinding stations.
Stakeholder Engagement & Reporting
- Prepare and present regular technical performance reports and improvement plans to Plant Management and senior stakeholders.
- Liaise with equipment OEMs, automation vendors and external consultants on technical upgrades, warranty issues and troubleshooting.
What are we looking for?
- 8-15+ years' experience in cement industry, including significant time in process or production management roles.
- Proven experience managing or leading a multi-disciplinary technical/engineering team, ideally across more than one site.
- Bachelor's degree in Chemical, Mechanical, Process, Mineral Processing, or Industrial Engineering (or closely related discipline); postgraduate qualifications are an advantage.
- Formal training or certification in process control, Six Sigma/Lean, or reliability methodologies is beneficial.
- Strong hands-on experience with pyroprocessing (kiln/preheater/cooler), Alternative fuels and grinding circuits (ball mills, vertical roller mills, classifiers).
- Experience with plant automation and control platforms (e.g. DCS, PLC/SCADA, advanced process control/expert systems) and working closely with automation/control engineers.
- Track record of driving measurable improvements in throughput, energy efficiency, product quality or reliability.
- Experience operating within formal safety, quality and environmental management systems in a heavy industrial setting.
- Exposure to capital projects, shutdown planning and OEM/vendor management is highly regarded.
What’s on offer?
- Permanent, full-time opportunity
- Join an industry aimed at offering value to the community & committed to Zero Harm
- Iconic market leader committed to driving sustainable outcomes
- We are Australian-owned and operated
- Opportunity to purchase additional leave
- Generous paid parental leave entitlements.
About Boral Cement
At Boral, we supply up to 4 million tonnes of cementitious products through our Berrima Clinker & Cement Manufacturing, Maldon Cement Grinding & Packaging, Marulan South Limestone Mine & Manufacturing, and Geelong Cement Grinding Operations. Boral Cement is working towards reducing carbon emissions by replacing 60% of fossil fuel in its manufacturing process with lower carbon alternative fuel. We have invested heavily in the development of Berrima’s alternative fuel project, to enable to the transition from coal to refuse derived fuels.
Our people provide solutions to help customers and stakeholders build a sustainable future in a changing world. Our values are what matters to us and guide our behaviours: Safety, Teamwork, Ambition, Accountability and Respect.
We’re proud of our legacy as a great Australian business and have a strong foundation to improve and continue fulfilling our purpose and what we do best - building something great.
Boral values and is committed to creating a diverse working environment and is proud to be an equal opportunity employer. All suitable applicants will receive consideration for employment without regard to race, colour, religion, gender identity or expression, sexual orientation, disability or age.
