Scale-Up Engineer

iPROOF•Decatur, IL

21h•$82,054 - $102,567•Onsite

About The Position

The Scale-Up Engineer is responsible for transferring fermentation processes from laboratory and pilot scales into demonstration environments. This role serves as the technical bridge between R&D, process development, manufacturing, quality, and engineering teams to ensure successful scale-up, robust process performance, and efficient commercialization. The engineer will lead process characterization, scale-up studies, technology transfer activities, batch execution support, troubleshooting, and continuous improvement initiatives for microbial, fungal, yeast, and/or heterotrophic algae fermentation and downstream processes.

Requirements

General Chemistry
Basic mathematical and physics principals
Unit operation knowledge (fermentation, filtration, spray drying)
Safety best practices in a manufacturing or pilot/demo environment
Biochemical engineering principles
Quality/food safety knowledge
Microsoft Office (Excel specific)
Statistical analysis, including multivariate data analysis
Understanding of process flows
Organization skills
Time management & prioritization
Excellent written and verbal communications
Critical thinking
Problem solving
Teamwork
Project Management
Maintains regulatory and technical awareness
Ability to coordinate efforts of others
Goal oriented
Learning-orientation
Economic consideration
Attention to safety, quality, sustainability
Collaborative
BS in Chemical, Bio, Engineering or a related field from ABET accredited institution (required)
2-3 years post graduation work experience (required)

Nice To Haves

Advanced degree in Chemical, Bio, Engineering or a related field (preferred)
Certification in Lean Six Sigma and Continuous Improvement (preferred)
Certification in Root cause analysis (5 why, fishbone, KT) (preferred)
Previous manufacturing or Pilot/Demo scale experience (preferred)
Previous experience in CDMO-type facility (preferred)
Previous experience in fermentation (preferred)
Previous experience in biomanufacturing-related downstream processing (preferred)

Responsibilities

Lead technology transfer projects from bench, pilot, or external development organizations into the iPROOF facility.
Develop and maintain technology transfer packages including; process descriptions, batch records, SOPs, process flow diagrams, material balances, and control strategies.
Coordinate knowledge transfer between iPROOF and customers and facilitate technical risk assessments and transfer readiness reviews.
Scale fermentation processes through pilot and demonstration scales to de-risk the technology.
Evaluate critical scale-up parameters including oxygen transfer (kLa), power input (P/V), mixing time, gas flow rates, heat transfer requirements, and feed strategies.
Support seed train development and scale progression strategies.
Design and execute experiments for media optimization, feeding strategies, and induction strategies.
Apply statistical and data-driven methods to improve process performance.
Identify opportunities to improve throughput, yield, and manufacturing economics.
Recommend unit operations needed and their order to obtain desired product.
Design and execute unit-operations-specific experiments for throughput and efficiency.
Provide on-floor technical support during fermentation campaigns.
Troubleshoot issues related to growth performance, titer, yield, productivity, contamination events, and process control.
Analyze process data and recommend corrective actions.
Support deviation investigations, root-cause analyses (RCAs), and corrective and preventive actions (CAPAs).
Collaborate with engineering teams on utility requirements, piping and instrumentation, CIP/SIP systems, and process controls.
Support FAT, SAT, commissioning, qualification, and startup activities.
Assist in equipment sizing and process modeling.
Author and review master batch records, process descriptions, technical reports, validation protocols, and technology transfer documents.
Ensure compliance with applicable food, feed, industrial biotech, or regulatory standards.
Maintain accurate project documentation and transfer records.
Manage multiple technology transfer and scale-up projects simultaneously.
Track timelines, budgets, risks, and deliverables.
Interface directly with customers, strategic partners, and commercial stakeholders.
Present project progress and technical findings to management.