Sajil Elayadathukudy Sunny
Auckland,AUK
Summary
Chemical & Materials Engineering postgraduate with over 2 years of manufacturing experience operating and monitoring industrial process equipment, including spray dryers, reactors, centrifuges, and ATFDs. Experienced in shift-based production environments with strong knowledge of GMP, SOPs, process monitoring, quality documentation, and troubleshooting. Proven ability to maintain safe and efficient plant operations while ensuring product quality and compliance. Seeking to apply my spray drying and process operations experience within a dairy manufacturing environment.
Overview
1
1
Certification
5
5
years of professional experience
Work History
Production Team
Teagle Poultry Processing
Henderson, NZ
08.2025 - Current
- Operate and set production machinery in a high-speed poultry processing environment, ensuring safe and efficient operations.
- Manage production throughput of approximately 30,000 chicken torsos per day, supporting daily production targets and product quality requirements
- Work in a high-speed, shift-based production environment, ensuring strict adherence to GMP and EHS standards
- Execute product changeovers between Boiler and Free-Range product lines, ensuring full compliance with SOPs, quality standards, and traceability requirements.
- Perform pre and in-process checks and maintain compliance with SOPs and hygiene protocols
- Support safe and efficient plant operations through teamwork and effective communication
- Demonstrate strong safety awareness in handling equipment and materials
- Collaborate with other team on planing and future production plans.
Food Service Staff Member
Kodurs Kitchen
Auckland, AUK
02.2024 - 08.2025
- Prepared and served food items in accordance with health and safety standards.
- Maintained the kitchen and dining.
- Assisted in inventory management, ensuring proper stock levels of ingredients.
- Collaborated with team members to deliver efficient service during peak hours by handling more than 50 customers.
Production Engineer
Amco Tea Factories
The Nilgiris, India
07.2023 - 12.2023
- Operated and optimised powder processing systems including dryers, sifters, and blending equipment
- Monitored process conditions to maintain consistent product quality and process stability
- Collaborated with maintenance teams to troubleshoot equipment issues and reduce downtime
- Supported continuous improvement initiatives to enhance operational efficiency and safety
Production Associate
Global Calcium Pvt Ltd
Hosur, India
10.2021 - 06.2023
- Operated and monitored multiple industrial spray dryers with production capacities of 1,000 kg and 2,000 kg per batch, ensuring stable process conditions and product quality throughout each shift.
- Managed spray dryer start-up, operation, monitoring, and shutdown activities while maintaining production targets and quality specifications.
- Operated and monitored chemical process equipment, including reactors, centrifuges, and ATFDs, in a continuous manufacturing environment.
- Supported troubleshooting and root cause analysis to resolve operational issues and improve process reliability
- Worked in a shift-based environment, ensuring smooth handovers and reporting production updates
- Followed strict GMP and safety protocols while handling chemicals and operating equipment
- Maintained Batch Manufacturing Records (BMRs) and ensured audit-ready documentation
- Collaborated with operations, QA, and maintenance teams to ensure safe and efficient plant performance
- Gained strong exposure to large-scale process operations, powder handling, and drying systems
- Conducted quality checks to maintain product standards and compliance with regulations.
Education
Master of Engineering - Chemical Engineering
University of Auckland
Auckland, NZ05-2025
Bachelor of Technology - Chemical Engineering
ESEC, Anna University
India01-2021
Skills
- Spray Dryer Operations
- Process Monitoring
- GMP & Food Safety Systems
- Quality Documentation
- Shift Operations
- Process Troubleshooting
- Production Record Keeping
- Continuous Improvement
IN-PLANT TRAINING
Fertilisers and Chemicals Travancore Limited (FACT), India- Dec 2019
- Gained exposure to large-scale sulphuric acid production using the Double Contact Double Absorption (DCDA) process
- Observed plant operations including sulphur combustion, gas purification, catalytic conversion, and absorption systems
- Developed understanding of effluent treatment processes, emission control systems, and environmental compliance in chemical plants
- Gained insight into process flow, heat integration, and industrial safety practices
Hindustan Organic Chemicals Ltd, India- Dec 2018
- Learned industrial production processes for acetone, ketones, and hydrogen peroxide
- Observed continuous process operations, separation techniques, and chemical handling systems
- Gained exposure to effluent treatment and wastewater management systems
- Developed understanding of process safety and large-scale chemical manufacturing.
Certification
- Natural Gas Engineering – NPTEL (2017) IIT Guwahati – Covered natural gas properties, reservoir engineering, production, and environmental safety.
- Waste to Energy Conversion – NPTEL (2018) IIT (Roorkee/Delhi) – Focused on thermal and biochemical waste-to-energy technologies and sustainability.
COMMUNITY & VOLUNTEER EXPERIENCE
EPSA, Committee Member, 2024-09, Present, Organised student support activities for postgraduates
Timeline
Production Team
Teagle Poultry Processing
08.2025 - Current
Food Service Staff Member
Kodurs Kitchen
02.2024 - 08.2025
Production Engineer
Amco Tea Factories
07.2023 - 12.2023
Production Associate
Global Calcium Pvt Ltd
10.2021 - 06.2023
Master of Engineering - Chemical Engineering
University of Auckland
Bachelor of Technology - Chemical Engineering
ESEC, Anna University