Consultant- Paper & Pulp Industry Full Time

Role: Consultant- Paper & Pulp Industry

Location: Noida

Role Overview

We are seeking a highly experienced Consultant specializing in Paper & Pulp manufacturing operations to drive transformational initiatives across process optimization, digital integration, and operational excellence. This role is designed for seasoned professionals with 10–15 years of hands-on experience in pulp and paper operations, consulting, or industrial transformation, who can seamlessly bridge deep process expertise with strategic advisory capabilities.

The successful candidate will operate across consulting engagements and client transformation programs, delivering measurable impact through strong domain knowledge, advanced digital solutions (ERP, MES, APS, Analytics, Industry 4.0), and proven stakeholder engagement skills.

This role demands a comprehensive understanding of paper & pulp manufacturing processes (wood handling to finishing), fiber processing, chemical recovery, utilities, and supply chain management, combined with expertise in technology-enabled optimization to improve productivity, sustainability, and profitability.

Key Responsibilities

1. Process Excellence & Operational Optimization

• End-to-End Value Chain Optimization:
• Lead initiatives across the complete pulp and paper manufacturing value chain—including wood preparation, pulping (mechanical/chemical), bleaching, stock preparation, paper machine operations, coating, finishing, and dispatch—identifying inefficiencies and implementing best practices.

• Pulping & Fiberline Optimization:
• Optimize kraft, sulfite, and mechanical pulping processes, focusing on yield improvement, chemical consumption, energy efficiency, and pulp quality consistency.

• Paper Machine Performance Improvement:
• Drive enhancements in machine efficiency (OEE), runnability, sheet quality, basis weight control, moisture uniformity, and reduction of breaks and downtime.

• Chemical Recovery & Utilities Optimization:
• Improve recovery boiler performance, causticizing efficiency, lime kiln operations, and optimize steam, power, and water usage across the mill.

• Quality Systems & Standards:
• Implement robust quality management systems, SPC, and compliance with ISO standards, FSC/PEFC certifications, and customer quality specifications.

• Sustainability & Resource Efficiency:
• Lead initiatives in water reduction, effluent treatment, energy conservation, fiber efficiency, and circular economy practices, aligned with ESG and net-zero targets.

2. Digital Solutions & Industry 4.0 Implementation

• Technology Roadmap Development:
• Architect and deploy digital transformation strategies integrating ERP, MES, APC (Advanced Process Control), QCS (Quality Control Systems), and supply chain systems.
• Advanced Analytics & Process Control:
• Implement AI/ML-driven process optimization for pulping, bleaching control, paper machine stability, predictive maintenance, and quality deviation minimization.
• IoT & Sensor Integration:
• Deploy real-time monitoring systems for consistency, moisture, basis weight, pressure, temperature, and equipment health across pulp and paper operations.
• Digital Twin & Simulation:
• Leverage digital twins for process simulation, bottleneck identification, and scenario-based optimization across fiberline, paper machines, and utilities.
• Data-Driven Decision Making:
• Enable real-time dashboards and KPIs for production, quality, energy, and sustainability metrics to support continuous improvement.

3. Consulting & Advisory Services

• Diagnostic Assessments:
• Conduct detailed mill diagnostics, benchmarking studies, gap analyses, and maturity assessments to identify operational and digital improvement opportunities.
• Solution Design & Business Case Development:
• Design targeted solutions for cost reduction, yield improvement, capacity expansion, and digital adoption, supported by strong ROI and risk assessments.
• Change Management & Stakeholder Engagement:
• Lead cross-functional transformation initiatives involving operations, maintenance, quality, IT, procurement, and leadership teams.
• Project Management & Delivery:
• Deliver end-to-end consulting engagements ensuring adherence to scope, timelines, budgets, and quality standards.
• Capability Building & Training:
• Develop SOPs, training programs, and knowledge transfer frameworks to enable sustainable improvements.

4. Supply Chain & Logistics Optimization

• Raw Material & Fiber Supply Optimization:
• Improve procurement and handling of wood, recycled fiber, and chemicals, including supplier management and cost optimization.
• Inventory & Production Planning:
• Enhance inventory control, production scheduling, and demand planning using APS and analytics tools.
• Distribution & Logistics:
• Optimize finished goods handling, warehousing, and distribution networks to improve service levels and reduce costs.
• Supply Chain Digitalization:
• Implement platforms for end-to-end visibility and real-time tracking across the value chain

5. Safety, Compliance & Risk Management (Optional)

• Safety Excellence:

Strengthen process safety, occupational health standards, and hazard prevention, especially in high-risk areas such as recovery boilers and chemical handling.

• Environmental Compliance:

Ensure adherence to environmental norms including effluent discharge, air emissions, odor control, and waste management.

• Risk Mitigation:

Identify operational and environmental risks and define mitigation strategies and business continuity plans.

Required Skills & Competencies

• Paper & Pulp Process Knowledge:

Strong understanding of kraft/mechanical pulping, bleaching chemistry, fiber properties, paper machine operations, coating technologies, and finishing processes.

• Utilities & Chemical Recovery Systems:

Expertise in recovery cycle (black liquor, recovery boiler, causticizing), steam/power generation, and water systems.

• Digital & IT Systems:

Experience with ERP (SAP, Oracle), MES, DCS/SCADA (ABB, Valmet, Siemens), QCS, and advanced analytics platforms.

• Data Analytics & AI:

Hands-on exposure to predictive maintenance, yield optimization models, and process analytics.

Consulting & Business Skills

• Strategic thinking and ability to link operations with business outcomes
• Strong financial modeling, ROI, and capital project evaluation capabilities
• Excellent stakeholder management across all organizational levels
• Proven change management and transformation leadership

Soft Skills

• Excellent communication and presentation skills
• Strong collaboration and cross-cultural teamwork ability
• Adaptability in dynamic environments
• High ethical standards and professionalism

Experience Requirements

• 10–15 years of progressive experience in:
• Paper & pulp manufacturing (production, process engineering, technical services) – Must have
• Industrial consulting in pulp & paper sector – Good to have
• Digital transformation in process industries – Must have
• Demonstrated success in delivering process improvements, cost savings, efficiency gains, or digital transformation initiatives in pulp & paper mills.
• Multi-site/global exposure preferred.

Educational Qualifications

• Bachelor’s degree (mandatory) in Chemical, Mechanical, Paper Technology, or Industrial Engineering
• Master’s degree (preferred) in MBA, Engineering Management, or related field

Key Performance Indicators (KPIs)

• Operational Efficiency: Improvements in yield, OEE, energy/water usage, and cost reduction
• Digital Adoption: Successful deployment of Industry 4.0 and analytics solutions with measurable ROI
• Quality Improvement: Enhanced product consistency and reduced variability
• Client Satisfaction: High NPS and repeat engagements
• Capability Development: Effective knowledge transfer and sustainable process improvements

Working

• Location: India (Pune / Noida preferred)
• Travel: Domestic and international travel required
• Visa: US B1/B2 (Preferred)