Process Engineer -Liaison R&D and Operations

Balchem•Faribault, MN

About The Position

The Process Engineer is responsible for optimizing and sustaining manufacturing processes to ensure safety, quality, compliance, and efficiency across the facility. This role serves as the primary liaison between R&D and Operations, translating new formulations and product designs into scalable, compliant, and cost-effective production processes. The position leads plant trials, manages technology transfer, and drives continuous improvement aligned to OEE, yield, and cost targets while upholding HACCP, GMP, allergen control, sanitation, and regulatory requirements (e.g., FDA/USDA, FSMA). This role is cross functional and interfaces with many different departments including R&D, Project Engineers, Manufacturing Personnel and others to help drive projects to successful completion.

Requirements

Bachelors degree in Chemical, Mechanical, Industrial, Food, or Manufacturing Engineering (or related).
5+ years in manufacturing environment (process engineering, production support, or scale-up).
Working knowledge of HACCP/FSMA, GMPs, CCPs, allergen control, sanitation/CIP, and basic microbiology/shelf-life concepts.
Demonstrated experience with SPC, root cause analysis, and CI methodologies.
Strong communication skills to translate technical concepts across R&D, QA, and Operations.

Responsibilities

Manufacturing Process Engineering Develop, optimize, and standardize processes to improve throughput, yield, and OEE, reducing waste (giveaway, rework, hold/release).
Lead structured root cause analysis (5 Whys, Fishbone, DMAIC) and implement CAPAs for process deviations, micro fails, or quality events.
Conduct time studies, line balancing, and process mapping to remove bottlenecks and minimize changeover, clean-in-place (CIP) time, and downtime.
Establish and maintain process parameters (e.g., temperatures, dwell times, viscosities, moisture/aw, pH) and corresponding control limits.
Create and update SOPs, batch sheets, job aids, control plans, PFMEAs, and one-point lessons for the production floor.
R&D / Operations Liaison Serve as the bridge between R&D, Plant Ops, and Supply Chain to ensure seamless NPI (new product introduction), reformulations, and material changes.
Translate lab/pilot recipes into manufacturable processesincluding scale-up parameters, equipment capability, and control strategies.
Plan and execute pilot runs, line trials, FPRs (first production runs)ensuring material readiness, line setup, sampling plans, and operator training.
Provide manufacturability and cost-in-use feedback early in development (ingredient sourcing, allergen segregation, sanitation impact, shelf-life).
Capture learnings, yields, and performance data during trials and communicate back to R&D for formulation or spec adjustments.
Equipment, Technology & Data Assess equipment capability; specify, commission, and validate mixing, thermal processing (HTST, UHT, retort, baking/frying), forming, filling/packaging, and cooling systems.
Lead process validation and capability studies (Cp/Cpk), MSA, and SPC monitoring for critical parameters (e.g., fill weight, seal integrity, temperature).
Use data analytics to monitor process drift and drive decisions; partner with Maintenance on reliability improvements (PMs, CBM, MTBF/MTTR).
Continuous Improvement & Cost Lead and support operational excellence initiatives (SMED, Kaizen, 5S, visual management) to reduce losses (scrap, micro/quality failures, overfill/giveaway, utilities).
Identify and implement automation/digitalization (e.g., inline vision, mass flow meters, PID control improvements, recipe management, MES/SCADA enhancements).
Build robust CIPs with financial impacttrack benefits to plan (yield %, OEE %, $/lb or $/case, energy/water intensity).
Training & Cross-Functional Collaboration Train operators and supervisors on new processes, CCP monitoring, sanitation impacts, and critical-to-quality attributes.
Work closely with Quality, Sanitation, Maintenance, Supply Planning/Procurement, EHS, and R&D to hit service, quality, and cost targets.