Senior Process Engineer

Ascent Industries Co.-posted about 2 months ago
Full-time • Mid Level
Danville, VA
501-1,000 employees
Primary Metal Manufacturing
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The Senior Process Engineer is a key technical leader, responsible for overseeing the design, optimization, and scaling of chemical batch manufacturing processes. This role provides senior-level engineering expertise and project leadership, serving as a primary point of contact for multiple customers while coordinating with a team of junior engineers to ensure safe, efficient, and high-quality production. The successful candidate will drive continuous improvement, manage technical aspects of customer relationships, and serve as a subject matter expert for the manufacturing team.

  • Ensure that all processes comply with regulatory standards (e.g., OSHA, EPA, FDA) and internal quality specifications.
  • Incorporate inherent safety principles and risk mitigation strategies into all process designs.
  • Participate in and lead incident investigations related to process safety or quality excursions.
  • Serve as the main technical point of contact for multiple customers, ensuring alignment on process design, product specifications, and project timelines.
  • Collaborate with customer R&D and product development teams to ensure successful technology transfer and validation for new product introductions.
  • Plan and manage engineering projects, including scope, budget, resource allocation, and timelines, for capacity expansion, automation, or process improvements.
  • Conduct presentations and prepare comprehensive reports for customers and senior management on project status, technical results, and performance metrics.
  • Provide technical guidance, mentoring, and mentorship to process engineers, shift supervisors, and technical staff.
  • Coordinate the daily activities and priorities of the engineering team, ensuring alignment with project goals and operational needs.
  • Conduct training for operators and manufacturing personnel on new and modified batch processes and equipment.
  • Facilitate cross-functional collaboration with other departments, such as Production, Quality Assurance, Maintenance, and Logistics.
  • Lead the development, scale-up, and validation of new batch processes from the R&D stage to commercial manufacturing.
  • Troubleshoot and resolve complex process and equipment issues to improve yield, efficiency, and product quality.
  • Conduct process simulations, risk assessments (e.g., HAZOPs), and data analysis to identify bottlenecks and implement corrective and preventative actions.
  • Utilize continuous improvement methodologies such as Six Sigma and Lean Manufacturing to drive efficiency and reduce waste.
  • Maintain all process documentation, including Process Flow Diagrams (PFDs), Piping and Instrumentation Diagrams (P&IDs), and Standard Operating Procedures (SOPs)
  • Assist in executing the annual capital plan for the business including project management and deployment of capital in the most efficient manner.
  • Bachelor's degree in chemical engineering or a related scientific discipline.
  • 7+ years of experience in a chemical manufacturing or batch processing environment.
  • Proven experience in process scale-up and optimization.
  • Hands-on experience with batch processing equipment such as reactors, mixers, blenders, and dryers.
  • Experience in project management, including budget and schedule management.
  • Demonstrated ability to effectively coordinate and lead a technical team.
  • Excellent analytical, problem-solving, and communication skills.
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