Python
Katlego Samson Maseko
Chemical Process Engineer
Johannesburg,GP
Summary
Experienced Chemical Engineer with 20 years in the FMCG industry, specializing in process optimization, risk assessment, and cost reduction. Proven ability to enhance operational efficiencies in processing and packaging. Led large-scale capex projects across Africa, managing timelines and collaborating with suppliers. Background includes various sectors, including beverages and home care, focusing on team leadership and operational excellence.
Overview
3
3
Certifications
20
20
years of professional experience
Work History
Production Manager
Zamani Chemicals
10.2025 - 03.2026
- Fostered safety culture while overseeing product making and packing, managed maintenance technician, and ensured compliance with quality management system (ISO 9001 and environmental management) for a team of 23.
- Coordinated production planning to ensure timely and efficient operations.
- Aligned demand volume with supply planning and production schedules to optimize workflow.
- Managed inventory using Pastel system to maintain stock levels and streamline order fulfillment.
- Warehouse management and transport planning
- Supervised the maintenance team to uphold equipment performance.
- Reporting: CEO
Unit Manager (Production Manager)
Unilever
05.2024 - 08.2025
- Managed safety, quality, environmental standards, people, production planning, and inventory.
- Safety incident investigation, unsafe acts, and unsafe conditions.
- People management and coaching for high performance.
- Implemented sustainability projects in water, energy, and waste management.
- Forecasting on cost and budgeting
- Forecasting on costs and budgeting
- Ensuring that sustainability projects are implemented, we have projects on the pipeline (water, energy and waste).
- Oversaw 64 employees across multiple shifts.
- Reporting: Plant Manager
Process Design Engineer (Home Care Africa)
Unilever
08.2022 - 05.2024
- Designed processes and managed projects for process plants.
- Reviewed projects to align with business strategy, leading process design, requirements, installation, and commissioning.
- Oversaw reporting functions related to African process design initiatives.
Production Manager
Zamani Chemical
05.2022 - 07.2022
- Handling discipline enquiries, managing overtime, managing more than 30 people (supervises and operations), managing making and packing of the products. Managing inputs raw material stock and output stock levels, Input stock into ERP system, planning production of the machines both make and pack. Budgeting for the factory, costing of the products.
- Handled discipline enquiries, managed overtime, and supervised over 30 employees in operations and production.
- Ensured safety standards for employees and product quality in the workplace.
- Reported to managing director on production metrics and operational performance.
Unit Manager
Unilever
09.2021 - 01.2022
- Management and coaching of CSO in the make plant, 65 employees in the make plant, approval of timekeeper, managing overtime for make plant. Managing stock level for chemicals in the crop plant, approval of weekly production plans and ensuring efficient changeovers, AM activities in the make plant, 5S activities, root cause analysis (5 why and 5G).
- Managed and coached CSO in the make plant, overseeing 65 employees.
- Reporting: Plant Manager
SENIOR UTILITIES & PROCESS ENGINEER
Unilever
04.2020 - 01.2021
- Led process control initiatives, managed innovation projects, and oversaw people management within WCM framework.
- Booking trials for make and pack projects. running trials in the make plant, report writing for trials. Managing the utilities and coaching process engineers. Focus improvement (Kaizens), Root cause analysis tools (5 why, 5W +1H and 5 G), Process points analysis, Process safety pillar (leading the pillar).
- Process control, Innovation projects, people management and WCM.
- Scheduled trials for make and pack projects, conducted trials in the make plant, and wrote reports on trial outcomes.
- Compiled and submitted process management reports to inform decision-making.
Unit Manager
Unilever
02.2018 - 04.2020
- Ensured safety compliance and quality standards in production processes.
- Safety, quality, people management, production planning and
- Reporting: Plant Manager
SENIOR PROCESS ENGINEER
Unilever
01.2017 - 01.2018
- Capital projects proposals. quotation with supplier, ordering of equipment, Installation and commissioning, optimization of equipment, booking trials for make and pack projects. Running trials in the make plant, report writing for trials. Coaching of Junior engineer, projects. Stakeholder management.
- Focus improvement (Kaizens), Root cause analysis tools (5 why, 5W +1H and 5 G), Process points analysis, Process safety pillar (leading the pillar).
- Developed capital project proposals, coordinated supplier quotations, ordered and commissioned equipment, optimized equipment performance, and organized trials for make and pack projects. Conducted trials in make plant, documented findings, coached junior engineers, and managed stakeholder relationships.
- Executed focus improvement initiatives (Kaizens) and applied root cause analysis tools (5 why, 5W +1H, and 5 G) to enhance process safety and performance.
- Managed process reporting as PROCESS MANAGER, ensuring clarity and accuracy in communication.
Regional Strategic sourcing and Innovation Planner (East Africa)
Unilever
04.2016 - 12.2016
- Innovation planning, strategic sourcing, capex forecasting and long-term capacity planning
- Developed project network on MS Project, analyzed innovation cycle time and reduced cycle time, managed project activities and accountabilities across functions (procurement, research and development, supply chain, regulatory), addressed and escalated project delays, led supply chain work stream, planned factory trials, and managed business waste.
- Executed intercompany sourcing projects for Unilever business case, led savings initiatives for East Africa, ensured business continuity, managed service level, and directed team in landing sourcing projects and risk management.
- Developing projects network on MS projects, analysis of innovation cycle time and reducing cycle time, managing projects activities and accountabilities all functions involved on the network (Procurement, research and development, supply chain, regulatory and other functions), addressing and escalating project delays, Leading supply chain work stream, planning of factory trials, run down plan and management of business waste.
- Reporting: Product Group- Strategic Planning Manager
Innovation Planner Home Care (Africa)
Unilever
01.2015 - 06.2015
- Managed projects, assessed risks, reduced business waste, and led supply chain work stream.
- Led new product innovation projects (renovation, innovations, and cost savings), facilitated project meetings, optimized project networks, and managed project networks (MS Projects) for Sunlight and Surf Africa across Nigeria, South Africa, Ivory Coast, Zimbabwe, Kenya, Ethiopia, and Ghana. Conducted risk assessments, developed mitigation actions, and tracked closure of actions.
- Managed the run down plan for raw materials and packaging materials. Communicated potential write offs to stakeholders.
- Manage run down plan of raw materials and packaging materials. Communicate any potential write off with stakeholders.
- Compiled detailed reports for innovation planning processes.
Technical Innovation Specialist (Southern Africa)
Brandhouse
01.2014 - 12.2014
- Strategic management of innovation project, management skills, and new product development.
- Managing new product development projects, managing cost saving projects. Managing innovation and continuous improvement trials in Southern Africa and imported products. Managing Capex projects, troubleshooting on new products and process improvements. Developing new timelines for projects, tracking the project using the MS projects timeline. Quotations from suppliers, Capex application, timelines (installation and Commissioning), managing progress of the installation with the site teams.
- Liaised with department of agriculture for import and export certificates, ensured documentation compliance with liquid and packaging legislation.
- Compiled reports on technical innovations
Technical support Manager (Southern Africa)
Brandhouse
09.2013 - 12.2013
- Managed innovation projects and new product development to enhance market competitiveness.
- Oversaw new product development and cost-saving projects, led innovation trials for Southern Africa and imported products, managed Capex projects, and troubleshot new products and process improvements. Developed project timelines, tracked progress using MS Project, and coordinated installation with site teams.
- Liaised with department of agriculture on import and export certification, updated documents to ensure compliance with legislation regarding liquid and packaging.
- Compiled technical reports for innovation projects.
Lean Manufacturing Officer
Entyce Beverages (National Brands- AVI)
07.2013 - 08.2013
- Visual management, continuous improvement, and savings projects
- Improved operational efficiencies in coffee and creamer processing and packing by facilitating continuous improvement initiatives and managing visual management system (shop-wave). Prepared and presented Pareto analysis, led root cause analysis using tools (fish bone diagram, basic condition, One-point lesson), and enhanced yield on instant processing plant. Facilitated improvements in ground coffee packing and reduced costs in creamer packing operations by sourcing sustainable technology solutions.
- Compiled reports on operational performance
Research and Development Process Technologist (Acting R & D Manager)
Entyce Beverages (National Brands-AVI)
07.2011 - 08.2013
- Management of trials in the process plant, Managing expenditure on coffee R & D budget, preparation of budgets for next fiscal, presenting on monthly management review meeting, contributing to 5 years’ research and development strategy, Internal auditing on QMS/environmental system, HACCP study writing and review, Participate in SHE program, Environmental system implementation, developing new specification for new products, Developing standard operating procedure (SOP), Conducting business process audits
- Managed trials in process plant and expenditures on coffee R & D budget; prepared budgets for next fiscal year; presented at monthly management review meetings; contributed to 5-year research and development strategy; performed internal audits on QMS/environmental system; wrote and reviewed HACCP studies; participated in SHE program; implemented environmental system; developed specifications for new products; created standard operating procedures (SOP); conducted business process audits.
- Compiled reports for R & D projects
Process Technologist (Utilities)
Heineken (Sedibeng brewery)
11.2010 - 06.2011
- Safety, SHEQ system. Management of wastewater treatment, RO water, boiler, ammonia, and CO2 plants.
- Provide technical support to Utilities plants, knowledge transfer to Utilities operators, standby for the Utilities plants. Conducting trials on different chemicals for water treatment, optimization of utilities, using TPM and kaizen projects in Utilities. Liaise with microbiologist on water and wastewater issues. Process troubleshooting, Reverse osmosis, Water and wastewater treatment plant, Boilers, CO2 recovery plant, Air compressor, Ammonia plant. Liaise with municipal officials on quality of water supply. Mass balance on the CO2 storage tanks, ordering CO2 from supplier.
- Ensured efficient biogas usage in boilers and optimized wastewater treatment processes. Authored startup procedure manuals for USAB reactors with digested sludge and managed discharge schedules from the brewery. Maintained high-quality biogas production from UASB reactors.
- Participated in HACCP studies and authored standard operating procedures (SOPs) for utilities. Conducted internal audits (5S, SHE, and quality) and developed sample plans for utilities. Applied statistical process control to ensure effluent discharge met specifications and presented quality parameters for utilities.
- Compiled and submitted research reports to inform decision-making as R&D Executive.
Research and Development Process Technologist
Entyce Beverages (National Brands limited- AVI)
07.2007 - 06.2010
- New product development, Process plant and SHEQ system
- Development of new recipes and changing bill of materials, conducting trials on small and large for new products, conducting trials for new raw material and suppliers, liaise with marketing on new product development, conducting cost analysis on bill of material, Conducting trials at CSIR. Internal auditing on QMS/environmental system, HACCP study writing and review, Participate in SHE programs, Environmental system implementation, implementing projects on reducing environmental impact. Process optimization, writing and reviewing of standard operating procedures (SOP), Writing manufacturing specifications, Plant troubleshooting, Daily product tasting, technology transfer to operators, Conducting mass and energy balance.
- Managed reporting for research and development projects.
Process Technician
Entyce Beverages (National Brands limited)
07.2006 - 06.2007
- SHEQ systems, Statistical process control Production and process
- Conducting trials on pilot plant and commercial plant, Process capacity and bottleneck analysis and improvement, OE & OEE analysis, Monitoring of cooling system and deionizer plant. Writing and reviewing of standard operating procedures (SOP), Plant troubleshooting, Plant commissioning after shutdown, Daily tasting of products. Drawing piping and instrumentation diagram (P & ID)
- Wrote and reviewed HACCP studies, participated in SHE programs, implemented environmental systems, wrote and reviewed short interval controls, and analyzed short interval controls to ensure compliance and safety.
- Relieve shift manager,, Managing a shift for both coffee and creamer plants, Investigating of downtimes in the process plants.
- Conducted trials on pilot and commercial plants.
- Reporting: R & D Executive
Trainee Process Technician
Entyce Beverages (National Brands limited)
03.2006 - 06.2006
- SHEQ systems, Statistical process control, Production, and process
- Internal auditing on QMS/environmental system, HACCP study writing and review. Participate in SHE programs. Environmental system implementation. Writing and reviewing short interval controls.
- Analysis of short interval controls, Investigating of downtimes in the process plants Creamer processing plant, Coffee processing plant. Conducting trials on pilot plant and commercial plant. Process capacity and bottleneck analysis and improvement. OE & OEE analysis, Monitoring of cooling system and deionizer plant. Writing and reviewing of standard operating procedures (SOP), Plant troubleshooting, Plant commissioning after shutdown
- Tasted products daily, drew piping and instrumentation diagrams (P&ID), and wrote weekly/monthly variance reports, presenting findings.
- Reason for Leaving: End of contract.
Trainee Laboratory Technician
First National Battery
03.2006 - 06.2006
- Conducted raw material testing and monitored cooling systems to ensure compliance with production processes.
- Performed sulphuric acid density testing, ion testing, and sodium sulphate testing to maintain laboratory accuracy.
- Conducted analyses of conductivity and total dissolved solids in laboratory samples.
- Monitored battery formation temperature and cooling water flow, conducted quality audits, and performed quality checks on final products to ensure operational standards.
- Reason for Leaving: End of contract.
Education
Post Graduate Diploma - Data science
01-2025
Certificate - Automation and instrumentation
Engineering Institute of Technology (EIT)
01-2023
Post Graduate Diploma - Management
Regent Business School
01-2020
Certification - Lean Six Sigma (Green Belt)
6 Sigma Learning
01-2020
Foundation - Project Management
University of Cape Town
01-2019
Bachelor of Technology - Business Administration
University of South Africa
01-2015
Bachelor of Technology - Chemical Engineering
University of Johannesburg
06-2010
National Diploma - Chemical Engineering
University of Johannesburg
12-2006
Skills
Production planning
Production line management
Advanced Microsoft Project
SAP
Data analysis
Cross-functional collaboration
Team development
Office suite proficiency
Accomplishments
- Increased overall productivity and quality by 10% by implementing training programs designed to increase performance levels.
- Proficiently supervised 5 production lines, oversaw materials inspection, scheduled production and conducted weekly physical inventories.
- Trained and supervised 20 production staff over 6 months time period
- Supervised team of 64 staff members.
- Documented and resolved savings projects which led to improved productivity
- Achieved high efficiency by introducing APC for spray dryer control
Additional Information
Language : English, Sepedi, Zulu
Company: AVI (Coffee and Creamer factory)
Coffee aroma distillation column
Design, installation, commissioning and training of operators
Capex: R 15 million
Innovation. Market share
Quadruple effect Evaporator
URS (User requirement specification of the plant) commissioning and training of operators
Capex: R 7 million
Increased capacity by more than 20%
Agglomeration Plant (Frisco granule introduction)
Formulation development, commissioning, and training of operators
Capex: R 10 million
Innovation, increased profit, and market share
Chicory Extraction plant
Running trials in Germany to qualify a new technology on extraction
Capex: R 25 million
Conversion cost savings
Heat exchanger
Design, installation and commissioning a fin tube heat exchanger to cool down coffee from spray dryer
Capex amount: R 3 million
Savings: R 1.2 million
spray dryer -Energy savings
Understanding the control loops of the spray dryer (energy use between natural gas)- Kaizen
No capex investment
R 1.5 million per year on gas consumption
Improving yield on the extraction system
Understanding the coffee extraction system and factors affecting yield - Kaizen
increase yield by 3%
Heineken (Sedibeng Brewery)
Wastewater treatment- Optimization
Improving the efficiency of the wastewater treatment plant
80% availability during peak (Sept-Dec)
Company
Brandhouse (Technical support manager-Innovation specialist)
Smirnoff Guarana - Innovation
Strongbow Gold - Innovation
Cape Velvet Chocolate
J & B Urban Honey
Smirnoff Vodka
Smirnoff Vodka flavors citrus, Blueberry
Smirnoff storm relaunch
Smirnoff flavors (Lemon and lime, Blueberry)
Archers’ flavors- production relocation
Company: Unilever (Innovation Planner - Africa, Sourcing, Process Engineer, Unit manager, Utilities Engineer, and Design Engineer)
Spray dryer -Energy savings
R 4 million per year and reduced gas consumption by 10%
Water perfume system
Omo - Ethiopia -Innovation
Sunlight - Ethiopia- Innovation
Sunlight Laundry bar - Nigeria
Sunlight - Powders relaunch in Southern Africa
Spray dryer in Ethiopia
Sourcing -Powders - Ivory coast (Sunlight and Omo)
Sourcing -Powder- Ghana( Sunlight and Omo)
Sourcing -Powder from Egypt to Kenya
Implementing digital spray dryer system
Automation on the palletizer
To increase OEE by 15% and its innovation
Dust extraction system
Pack machine project
Software
Visio
MS Projects
Excel
Certification
Lean Six Sigma green belt
Interests
Marathons
Reading books
My career has been profoundly influenced by my passion for chemical processes
- My career has been profoundly influenced by my passion for chemical processes, a fascination that guided me toward the dynamic field of chemical engineering. Commencing my academic journey with a Bachelor of Technology in Chemical Engineering.
- I have consistently expanded my skills and knowledge, as evident in my academic achievements:
Timeline
Production Manager
Zamani Chemicals
10.2025 - 03.2026
Automation and instrumentation
12-2024
Unit Manager (Production Manager)
Unilever
05.2024 - 08.2025
Process Design Engineer (Home Care Africa)
Unilever
08.2022 - 05.2024
Production Manager
Zamani Chemical
05.2022 - 07.2022
Unit Manager
Unilever
09.2021 - 01.2022
SENIOR UTILITIES & PROCESS ENGINEER
Unilever
04.2020 - 01.2021
Lean Six Sigma green belt
01-2020
Project Management
09-2019
Unit Manager
Unilever
02.2018 - 04.2020
SENIOR PROCESS ENGINEER
Unilever
01.2017 - 01.2018
Regional Strategic sourcing and Innovation Planner (East Africa)
Unilever
04.2016 - 12.2016
Innovation Planner Home Care (Africa)
Unilever
01.2015 - 06.2015
Technical Innovation Specialist (Southern Africa)
Brandhouse
01.2014 - 12.2014
Technical support Manager (Southern Africa)
Brandhouse
09.2013 - 12.2013
Lean Manufacturing Officer
Entyce Beverages (National Brands- AVI)
07.2013 - 08.2013
Research and Development Process Technologist (Acting R & D Manager)
Entyce Beverages (National Brands-AVI)
07.2011 - 08.2013
Process Technologist (Utilities)
Heineken (Sedibeng brewery)
11.2010 - 06.2011
Research and Development Process Technologist
Entyce Beverages (National Brands limited- AVI)
07.2007 - 06.2010
Process Technician
Entyce Beverages (National Brands limited)
07.2006 - 06.2007
Trainee Process Technician
Entyce Beverages (National Brands limited)
03.2006 - 06.2006
Trainee Laboratory Technician
First National Battery
03.2006 - 06.2006
National Diploma - Chemical Engineering
University of Johannesburg
Bachelor of Technology - Chemical Engineering
University of Johannesburg
Bachelor of Technology - Business Administration
University of South Africa
Foundation - Project Management
University of Cape Town
Certification - Lean Six Sigma (Green Belt)
6 Sigma Learning
Post Graduate Diploma - Management
Regent Business School
Certificate - Automation and instrumentation
Engineering Institute of Technology (EIT)