Job Description

ABOUT AGRATASAgratas is a wholly owned subsidiary of Tata Sons. We design, develop and manufacture high-quality, high-performance, sustainable batteries applied to multiple use cases in the mobility and energy sectors, to match our customers’ requirements. Agratas is a scale-up business with a start-up mentality, driven by our pursuit of green growth and technological progress. We develop next-generation battery technologies at our state-of-the-art R&D Innovation Hubs in India and the UK. ROLE PROFILEThe OpportunityWe are seeking a technically skilled and detail-oriented Process Engineer to lead web handling and tension control systems within the electrode coating process of our Li-ion cell manufacturing line. The candidate will be responsible for designing, optimizing, and troubleshooting web transport systems to ensure coating quality, edge alignment, and film integrity throughout the coating section. Business Expertise:Requires understanding of manufacturing operations, quality systems, and how different departments (like R&D, supply chain, and maintenance) work together. Knowledge of industry trends and competitor technologies is essential.Problem Solving:Deals with complex issues such as process variability, yield loss, and equipment reliability. Requires analytical thinking, innovation, and adaptability to environmental factors like humidity and material behavior.Nature & Area of Impact:Directly impacts production efficiency, quality, and cost. Influences the performance of teams and departments, contributing to business goals and overall competitiveness. PERSON PROFILEKey Accountabilities and ResponsibilitiesProcess Design & Optimization Design and optimize web handling systems for uniform coating on electrode foils (Al & Cu).Define and validate tension profiles across different coating zones: unwinding, coating, drying, rewinding.Optimize parameters for web speed, roller alignment, nip pressure, and dynamic tension compensation.Control Systems & Automation Develop and fine-tune closed-loop tension control systems using load cells, dancers, brakes, and servo drives.Work with automation engineers to integrate PLC/SCADA/HMI for real-time monitoring and control.Ensure synchronization across multiple web zones (e.g., dual-sided coating, segmented dryers).Coating Quality & Web Stability Prevent web defects such as wrinkles, misalignment, telescoping, and flutter.Maintain coating uniformity by ensuring consistent web tension and speed during dynamic operation.Analyze the impact of web tension on slurry coating behavior and drying consistency.Scale-up & Equipment Commissioning Support commissioning and ramp-up of new coating lines and upgrades.Collaborate with OEMs on web path design, tension control logic, roller selection, and automation integration.Maintenance, Monitoring & Troubleshooting Develop standard operating procedures for tension control systems.Perform root cause analysis and resolve issues related to web breakage, coating defects, or tension instability.Conduct periodic calibration and maintenance of load cells, encoders, and web guide systems.Documentation & Cross-functional Support Document tension control strategy, process settings, and alarm logic.Interface with quality, maintenance, and R&D teams to align web handling design with product requirements and experimental trials.Knowledge, Skills and Experience EssentialDesign and refine web transport systems to ensure smooth movement of electrode sheets during coating, drying, and winding stages without defects or misalignment.Maintain precise control of web tension throughout the process to prevent issues such as wrinkles, breaks, or misregistration, ensuring consistent product quality.Hands-on experience in tension control systems, servo drives, web guiding, and dynamic roller systems.Strong understanding of mechanics of continuous webs, foil deformation, and process-material interaction.Proficient with tools like AutoCAD, SolidWorks, and control system platforms (e.g., Siemens, Allen Bradley).Use sensors, load cells, and control software to continuously monitor tension and alignment, and make real-time adjustments for optimal performance.Identify and resolve process abnormalities such as web drift, telescoping, or slack zones to minimize downtime and material waste.Ensure web handling components like rollers, brakes, tension controllers, and guiding systems are properly maintained and calibrated for reliable operation.Work closely with coating, maintenance, and automation teams to integrate and improve web handling strategies in line with production goals. DesiredDeep understanding of web handling mechanics, including tension zones, nip points, speed differentials, and dancer/feedback control systems.Proficiency with PLCs, HMI interfaces, and closed-loop control systems used for web alignment and tension regulation.Experience with data analysis and process control tools (e.g., SPC, Minitab) to monitor performance, identify trends, and implement corrective actions.Familiarity with process data acquisition and analysis tools to monitor web performance and drive continuous improvement.Strong communication and cross-functional collaboration skills to work effectively with R&D, quality, and production teams.Role Specific Qualifications/CertificationsBachelor’s or master’s degree in chemical engineering, Materials Science, Mechanical Engineering, or a related field3-10 years of experience in a manufacturing environment, preferably in battery, chemical, or pharmaceutical industries.