Process Engineer

Flyttr; San Antonio (TX); On-site; USD 85,000 - 120,000; Full time

Job summary

Flyttr, a biosecurity company based in the United States, is seeking a Process Engineer to develop, optimise and scale insect mass-rearing processes supporting research, product development and commercial operations.

You will work with Engineering, Quality, Operations and Scientific teams to identify opportunities for efficiency, quality, capacity and cost improvements throughout the production lifecycle, from concept to implementation.

Qualifications

• Bachelor's degree in Engineering or related field.
• Experience applying engineering principles to process development or manufacturing.
• Strong analytical and problem-solving abilities with data interpretation.
• Experience designing and executing experiments or trials for process improvement.
• Ability to identify root causes and implement practical solutions.
• Excellent communication and cross-functional collaboration.
• Strong organisational and project management skills.
• Proficiency with Microsoft Word, Excel, PowerPoint and Outlook.
• Ability to work independently and in teams in a fast-paced environment.
• Knowledge of Lean Manufacturing, Six Sigma or CI methodologies.

Responsibilities

• Design and optimise insect mass-rearing processes to improve efficiency and cost.
• Analyse production data to identify trends and bottlenecks.
• Plan and evaluate process improvement trials and experiments.
• Scale-up rearing processes from lab to production.
• Establish operating procedures and performance metrics.
• Collaborate with engineering, operations and biology teams.

Skills

Analytical skills

Problem-solving

Communication skills

Project management

Lean Six Sigma knowledge

Independent work

Education

Bachelor's degree in Engineering or related

Tools

MS Word

MS Excel

MS PowerPoint

MS Outlook

Job description

About Us

We are a team of passionate individuals from 15 countries developing the world’s first biosecurity platform built to combat critical pest threats to human health, food security and the environment.

With a deep commitment to trust, integrity and collaboration, Flyttr has become the trusted partner of governments, industries, philanthropies and communities seeking to make bold advancements on the biggest pest threats of our time. We work with urgency because lives and livelihoods depend on it. Successful candidates will find Flyttr to be an exhilarating place to do their best work and will find that every person at Flyttr plays a critical role in a dynamic, exciting, team-oriented culture.

Purpose of the Job

The Process Engineer will play a key role in developing, optimising and scaling Flyttr's insect mass-rearing processes to support research, product development and commercial operations. The role will focus on improving efficiency, quality, capacity and cost-effectiveness throughout the production lifecycle.

Working closely with Engineering, Quality, Operations and Scientific teams, the Process Engineer will identify opportunities to improve rearing systems, implement process improvements and support the deployment of scalable production solutions. The successful candidate will contribute to projects from initial concept and process development through to validation, implementation and continuous improvement.

This role requires a practical and analytical individual who can combine engineering principles with biological understanding to solve complex challenges in insect production. Strong communication skills, a continuous improvement mindset and a passion for Flyttr's mission will be key to success.

Responsibilities

Process Development & Optimisation

• Design, develop and optimise insect mass-rearing processes to improve efficiency, capacity, quality and cost-effectiveness.
• Analyse production data to identify trends, bottlenecks, process variability and opportunities for improvement.
• Develop, execute and evaluate process improvement trials and experiments.
• Support the scale-up of rearing processes from laboratory and pilot environments into operational production.
• Establish process parameters, operating procedures and performance metrics to ensure consistent outcomes.
• Apply Lean, Six Sigma, continuous improvement or equivalent methodologies to improve operational performance.

• Establish process control strategies to ensure repeatability and consistency at scale.

• Work with biological teams to understand insect life-cycle requirements and translate biological needs into scalable operational processes.

Production Support

• Provide day-to-day engineering support to insect production operations.
• Investigate process deviations, quality issues and operational challenges, identifying root causes and implementing corrective actions.
• Support troubleshooting activities to minimise downtime and maintain production targets.
• Monitor process performance and recommend improvements to maximise yield, throughput and product quality.
• Assist in capacity planning and process design to support future business growth.

Data Analysis & Reporting

• Collect, analyse, interpret, and visualise operational and experimental data to support decision-making.
• Develop reports, dashboards and performance metrics to monitor process effectiveness.
• Present findings and recommendations to technical and non-technical stakeholders.
• Support data-driven decision making through effective use of statistical and analytical tools.

Cross-Functional Collaboration

• Work closely with Engineering, Operations, Biology, Quality, Regulatory and Data Science teams on multidisciplinary projects, communicating complex process engineering concepts clearly to non-experts.
• Contribute technical expertise during the design and implementation of new equipment, facilities and production systems.
• Support validation activities for new processes, equipment and operational changes.
• Collaborate with external suppliers and partners as required.

Compliance, Quality & Safety

• Ensure all activities comply with company policies, quality standards, biosafety requirements and health and safety regulations.
• Support risk assessments and process safety reviews.
• Assist in the development and maintenance of Standard Operating Procedures (SOPs) and work instructions.
• Promote a culture of safety, quality and continuous improvement throughout operations.

Skills, Experience, and Education Requirements

Essential

• Bachelor's degree (or equivalent) in Chemical Engineering, Process Engineering, Industrial Engineering, Manufacturing Engineering, Biological Engineering or a related discipline.
• Experience applying engineering principles to process development, optimisation or manufacturing environments.
• Strong analytical and problem-solving skills with the ability to handle and interpret complex datasets.
• Experience designing and executing experiments, trials or process improvement initiatives.
• Ability to identify root causes and implement practical solutions.
• Excellent communication skills and ability to work effectively across multidisciplinary teams.
• Strong organisational and project management skills.
• Proficiency with Microsoft Word, Excel, PowerPoint and Outlook.
• Ability to work both independently and collaboratively in a fast-paced environment.
• Knowledge of Lean Manufacturing, Six Sigma or Continuous Improvement methodologies
• Demonstrates a practical, solutions-focused mindset.

Desirable

• Experience within biotechnology, agriculture, life sciences, food production, fermentation, insect rearing or biological manufacturing environments.
• Knowledge of Lean Manufacturing, Six Sigma or Continuous Improvement methodologies.
• Experience with statistical analysis and process monitoring tools.
• Experience supporting scale-up activities from R&D to production environments.
• Familiarity with automation, production systems or engineering design principles.
• Experience working within regulated or quality-controlled environments.
• Knowledge of insect production, entomology, biological systems or agricultural technologies.
• Experience using data visualisation, reporting or dashboarding tools.

Hazards and Safety Information

• Exposure to construction-related activities and equipment installation is expected e.g. noise, dust, and changing site conditions.
• Occasional manual handling e.g. carrying and moving of materials and equipment is required, likely up to 25 pounds.
• The working insectary conditions are warm and humid.
• Compliance with safety procedures and PPE will be required, including nitrile gloves to be worn at all times in the labs.
• Materials handled include animal products and derivatives (including dairy).

Behavioural Requirements

• Commitment to, and passion for, the Flyttr mission and values.
• Responsive to the needs of an international business working across different time zones, adapting working patterns in-line with business requirements.
• Positive, humble, co-operative and professional always.
• Works with urgency and solves things promptly.
• Resilient and persistent in an innovative and constantly changing environment.
• Proactive, resourceful, and comfortable building processes from scratch.
• Values collaboration and works effectively with global colleagues.

We are an Equal Opportunity Employer. All qualified applicants will receive consideration without regard to age, disability, race, religion or belief, sex, sexual orientation, pregnancy, marital status, medical condition, gender reassignment, veteran status, or any other status protected by law.