Feed Mill Supervisor with 10+ Years Leadership Experience
Resume:
CORE SKILLS
Feed Mill Operations Management
Production Planning & Scheduling
Pelleting & Conditioning
SCADA System Operation
Process Optimization
Lean Manufacturing / Six Sigma
KPI Monitoring & OEE Analysis
Team Leadership & Development
Cross-Functional Coordination
Preventive Maintenance Planning
FIFO Inventory Management
Capital Project Management
Technical Proposal Evaluation
TECHNICAL EXPERTISE
Bühler Processing Lines
Andritz Coaters
Amandus Kahl Processing Lines
FAMSUN Processing Lines
Steam Specifications
Laboratory Analytical Equipment
EDUCATION
B.Sc. Agriculture
Animal, Poultry & Aquaculture Science
Kafr El-Sheikh University 2016
LANGUAGES
Arabic — Native
English — Advanced
SOFTWARE & TOOLS
Microsoft Excel (Advanced)
SCADA / HMI Control Systems
ERP / MES Production Reporting
Production Reporting Software
AI-Assisted Analysis Tools
NUTRITION KNOWLEDGE
Broiler & Layer Feed Programs
Breeder & Grandparent Diets
Aquaculture & Cattle Nutrition
Specifications
PROFESSIONAL SUMMARY
Results-driven Feed Mill Production Manager with 9+ years of progressive experience spanning quality control, production engineering, and senior production management across Egypt, Jordan, and Iraq. Proven track record of leading high-capacity feed production operations up to 240 t/h and 1,000,000+ MT per year, utilizing Bühler, Andritz, and Amandus Kahl technologies across multi-line, multi-product facilities. Deep expertise in pellet mill optimization, SCADA-driven process control, cross-departmental coordination, and full compliance with ISO 22000 and HACCP standards. Recognized for spearheading greenfield plant commissioning, delivering a 95% reduction in reworked product, and achieving dual ISO certification. Adept at building high-performance teams, driving continuous improvement initiatives, executing capital equipment upgrade projects, and delivering measurable gains in OEE, throughput, and operational uptime.
PROFESSIONAL EXPERIENCE
Production Manager
Etihad – Rayan for Oil Extraction & Feed Mill Babil / Iraq Oct 2024 – Present Facility Profile: 2 plants 3 production lines each; 6 Bühler pellet mill lines (40 t/h per line); total combined capacity of 240 t/h; producing broiler, layer, breeder, and grandparent compound feeds; annual throughput exceeding 1,000,000 MT.
• Directed end-to-end production operations across two large-scale compound feed plants, ensuring full alignment between daily output targets, integrated farm resource requirements, and commercial sales commitments across all product categories.
• Developed and managed detailed production schedules and capacity plans for flexible mash and pelleted feed lines, strategically balancing product changeovers to minimize line downtime, eliminate bottlenecks, and consistently maximize plant throughput.
• Coordinated with Premix Plant leadership to establish and maintain micro-nutrient preparation priorities that were fully synchronized with master production plans, safeguarding uninterrupted feed formulation across all processing lines.
• Generated comprehensive daily and long-term operational performance reports covering key metrics including production output rates, line availability, equipment OEE, scheduled and unscheduled downtime events, and structured root-cause failure analysis.
• Partnered with the Engineering Department to design, schedule, and execute planned preventive maintenance (PM) programs across all critical assets, while maintaining rapid- response protocols for unscheduled equipment failures to minimize production disruption and protect throughput continuity.
• Maintained strategic coordination with the Quality Department to integrate real-time laboratory analysis results into active production workflows, enabling immediate corrective action to preserve product specifications, nutritional accuracy, and food safety standards throughout all manufacturing and packaging stages.
• Chaired periodic cross-functional operational review meetings with production, quality, engineering, and logistics teams to assess manufacturing performance, identify process inefficiencies, and implement structured improvement initiatives that reinforced a sustained culture of operational excellence.
• Supervised and optimized all pelleting, grinding, steam conditioning, and die selection parameters to consistently maintain target Pellet Durability Index (PDI), moisture content, and bulk density specifications across all product types and seasonal conditions.
• Oversaw raw material receiving operations in direct collaboration with quality engineers, rigorously verifying supplier compliance with procurement specifications, HACCP Critical Control Points (CCPs), and traceability documentation requirements.
Kafr El-Sheikh, Egypt
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LinkedIn Profile
HESHAM ELBHAIRY
Feed Mill Production Manager
9+ Years in Feed Mill Operations • Egypt Jordan Iraq
• Evaluated and implemented line modification and process improvement projects in close partnership with Bühler process engineers, achieving measurable and sustained reductions in material waste, production cycle time, and specific energy consumption per ton.
• Reviewed, evaluated, and adjudicated technical proposals submitted by Andritz, Bühler, and Amandus Kahl for capital equipment upgrades and process enhancements, delivering data-driven investment recommendations and technical justifications to senior management for final decision-making.
• Defined clear role responsibilities, competency frameworks, and quantifiable performance targets for all direct reports within the production organization; conducted structured periodic performance reviews to drive individual accountability, professional growth, and team cohesion.
• Managed the full lifecycle of human resource functions within the production department, including talent acquisition and structured onboarding, employee motivation and engagement programs, performance coaching, and disciplinary procedures where required.
• Maintained optimal inventory levels for both raw materials and finished product stocks across all product lines, ensuring responsive and accurate fulfilment of evolving specification requirements and fluctuating volume demands from farms and commercial customers.
Production Manager
Khayrat Al Shamal Feed Mill Al Mafraq, Jordan Oct 2023 – Oct 2024
• Developed and executed detailed daily production plans by systematically integrating farm demand forecasts, commercial sales orders, and current warehouse stock positions, achieving zero stockout incidents throughout the tenure.
• Managed forward-looking raw material inventory projections by continuously monitoring consumption rates against production schedules, triggering replenishment purchase orders well in advance of requirements to maintain uninterrupted continuous line operations.
• Ensured full compliance with preventive maintenance schedules across all production assets and coordinated emergency repair activities in close collaboration with the engineering team, minimizing mean time to repair and protecting production continuity.
• Monitored Quality Department analytical outputs in real time, implementing rapid and targeted corrective actions to uphold finished product safety, nutritional accuracy, and physical consistency throughout all processing and packaging operations.
• Supervised and fine-tuned pelleting, grinding, steam conditioning parameters, and micro- nutrient mixing operations, consistently meeting formulation accuracy targets and all pellet physical quality benchmarks including PDI, moisture, and fines percentage.
• Managed SCADA system operations in coordination with plant operators, maintaining process parameter stability across all production lines and enabling rapid identification and response to process deviations before they could impact product quality or output volume.
• Coordinated with certified external service providers for periodic steam boiler inspections and precision calibration of all dosing and weighing scales, ensuring continued regulatory compliance and the highest standards of batch weighing accuracy.
• Spearheaded line efficiency improvement initiatives in direct collaboration with FAMSUN process technicians, implementing targeted engineering modifications that achieved measurable reductions in raw material waste per tonne and consistent increases in hourly throughput rates.
Production Shift Leader
Abo-Donkol Feeds Alexandria, Egypt Jan 2022 – Oct 2023
• Led comprehensive shift-level production planning and real-time workforce coordination across a team of production engineers and technicians, consistently achieving daily output targets while strictly maintaining all quality, food safety, and occupational health standards.
• Monitored raw material consumption rates and storage silo inventory levels throughout each shift, issuing accurate and timely replenishment requests to warehouse and procurement teams to prevent supply gaps and avoid unplanned production stoppages.
• Supervised pelleting, grinding, steam conditioning, and micro-nutrient mixing operations during all active shifts, ensuring strict adherence to approved formulation parameters, process specifications, and pellet physical quality benchmarks on every batch processed.
• Authored comprehensive daily and long-term production shift reports documenting output volumes, equipment performance, process deviations, operational incidents, and corrective measures implemented, providing management with accurate and actionable intelligence for decision-making.
• Designed, developed, and standardized a suite of structured production reporting templates to systematically capture comprehensive process performance data across all production stages, establishing a consistent benchmarking framework for ongoing performance tracking and trend analysis.
• Actively participated in the planning, documentation, and implementation of ISO 9001 Quality Management and ISO 22000 Food Safety Management Systems, making direct and significant contributions to two fully successful third-party certification audit cycles. Production Engineer
Abo-Donkol Feeds Alexandria, Egypt May 2019 – Jan 2022
• Supervised all pellet press operations, including the systematic selection of die specifications, optimization of steam conditioning parameters, and precise adjustment of cooler settings, consistently maintaining target PDI, moisture content, and hourly throughput across all product codes.
• Monitored and verified micro-nutrient mixing cycle accuracy by confirming precise ingredient weighing, complete ingredient discharge, and the achievement of a fully homogeneous blend quality on every production batch, safeguarding nutritional specification compliance.
• Coordinated closely with the Quality Assurance Department to integrate real-time analytical laboratory results into active production operations, enabling continuous and immediate process adjustments to ensure consistent finished product nutritional and physical quality across all batches.
• Oversaw all finished product loading and dispatch operations in direct collaboration with the warehouse team, rigorously verifying FIFO stock rotation compliance, load integrity, accurate quantity recording, and completeness of all associated documentation.
• Managed pellet packing line operations and performed regular calibration of automatic weighing parameters to maintain strict compliance with approved weight tolerances and packaging specifications across all product variants and pack sizes.
• Operated all feed processing lines and pellet presses through the integrated SCADA control system and delivered structured training programs for plant technicians covering system navigation, standard operating procedures, process parameter interpretation, and emergency shutdown protocols.
• Coordinated with the Maintenance Department to systematically document, prioritize, and track all equipment faults and service activities from initial report through to verified resolution, contributing to the continuous improvement of equipment reliability and planned maintenance effectiveness.
• Managed daily raw material silo allocation and supply requirements by calculating precise production batch needs, cross-referencing live silo inventory data, and coordinating timely material transfers from raw material storage to maintain fully uninterrupted production line supply.
Quality Control Engineer
Abo-Donkol Feeds Alexandria, Egypt Oct 2018 – May 2019
• Conducted comprehensive physical and chemical analysis of all incoming raw material consignments, issuing formal acceptance or rejection decisions in strict accordance with established quality specifications and supplier qualification criteria.
• Prepared, maintained, and safeguarded daily quality control and laboratory analytical records with full data traceability, ensuring complete documentation availability for internal management reviews, external regulatory audits, and customer quality assurance requirements.
• Monitored all active manufacturing stages across the production facility to verify continuous compliance with process hygiene standards, food safety protocols, and the full suite of quality management system requirements.
• Performed systematic sampling and multi-parameter analysis of raw materials, work-in- progress intermediate products, and finished goods at all defined control points, confirming conformance to approved nutritional, physical, and microbiological product specifications.
• Commissioned, operated, calibrated, and maintained all laboratory analytical instruments and testing equipment in direct coordination with specialist equipment suppliers, ensuring ongoing instrument accuracy, reliability, and regulatory traceability.
• Monitored all designated Critical Control Points (CCPs) within the HACCP plan, documented CCP monitoring records, and implemented and verified corrective actions for all CCP deviations to continuously safeguard product safety and maintain regulatory compliance.
• Contributed directly to the development, documentation, and operational implementation of the ISO 9001 Quality Management System and HACCP food safety management plan, participating actively in both internal preparation audits and formal third-party external certification audits.
Feed Production Engineer
AL Nahar Poultry Idku, Al Buhaira, Egypt Aug 2016 – Oct 2018
• Managed and supervised all raw material receiving workflows, including verification of delivery documentation accuracy, quantity reconciliation against purchase orders, and systematic conduct of initial quality inspections for all incoming raw material shipments.
• Supervised dosing and batch mixing operations, verifying the accurate weighing and complete discharge of all macro and micro ingredients to ensure consistent batch composition, uniform ingredient distribution, and full feed homogeneity on every production run.
• Maintained regular liaison with the feed nutritionist to monitor, review, and promptly incorporate all approved formulation updates and recipe modifications into active production schedules, ensuring nutritional accuracy and full traceability of all recipe changes.
• Operated the complete feed production process, including raw material intake, grinding, dosing, mixing, pelleting, cooling, and finished product handling, through the integrated SCADA control system, maintaining all process parameters continuously within approved operational ranges.
KEY ACHIEVEMENTS
• Spearheaded the full greenfield commissioning and production ramp-up of the Abo- Donkol Feed Mill facility in direct partnership with the Amandus Kahl specialist commissioning team, successfully bringing all three processing lines from mechanical completion to full design capacity on schedule and within budget.
• Delivered a strategically significant multi-line capacity and product range expansion project at Rayan Feed Mill, overseeing the complete installation, commissioning, and integration of higher-capacity Bühler pellet mill lines, KAHL expander systems, and Andritz post-pellet coater units, resulting in a substantial increase in both plant throughput capacity and value-added product portfolio breadth.
• Achieved a 95% reduction in reworked and off-specification finished feed through the systematic and disciplined optimization of all production line parameters, precision calibration of pelleting and conditioning equipment, and the standardization of pellet geometry control procedures across all product codes.
• Engineered and implemented a multi-line operational flexibility enhancement program that substantially reduced unplanned breakdown-related production downtime by enabling rapid seamless product switching and efficient parallel line operation, significantly improving overall plant availability and customer service responsiveness.
• Achieved ISO 9001 Quality Management System and ISO 22000 Food Safety Management System certifications on two separate occasions at the Abo-Donkol facility, leading the preparation of audit documentation packages, conducting structured internal pre- certification audits, and driving the implementation of all required corrective and preventive actions identified during the certification process.
• Managed a structured and thorough technical evaluation and commercial negotiation process with global equipment suppliers including Andritz, Bühler, and Amandus Kahl, securing optimized capital equipment upgrade packages and service agreements that were fully aligned with strategic production KPI targets and approved project budget parameters.
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