Senior Process Engineer
Sustana
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Benefits offered by this job
Job summary
Sustana in Wisconsin seeks a Senior Process Engineer to lead recycled fiber manufacturing, owning the process from receipt to finished product. You will optimize safety, quality, throughput, reliability, and cost while driving continuous improvement, standardization, automation, and capital projects.
Working closely with Operations, Maintenance and EHS, you will leverage data analysis, troubleshooting, and process control strategies to improve performance and support long-term business
Qualifications
- Bachelor's Degree in Chemical Engineering, Paper Science, Paper Engineering, or related field.
- 7–10 years of process engineering in pulp and paper or recycled fiber environments.
- Experience with process optimization and improvement initiatives in continuous-process manufacturing.
- Experience with automation projects and capital improvements in a 24/7 plant.
Responsibilities
- Lead process ownership and optimize throughput, quality, and OEE.
- Develop SOPs, centerlines, and best practices for process control.
- Lead troubleshooting, root cause analysis, and corrective actions.
- Collaborate with Operations, Maintenance and EHS on capital projects and improvements.
- Support safety, environmental compliance, and cost reduction initiatives.
Skills
Education
Tools
Job description
The Senior Process Engineer serves as the technical leader and process owner for Sustana's recycled fiber manufacturing operations, providing expertise across the production process from wastepaper receiving through finished product manufacturing. This role is responsible for optimizing safety, quality, throughput, reliability, and cost performance while driving continuous improvement initiatives, process standardization, automation enhancements, and capital projects. Working closely with Operations, Maintenance and EHS departments, the Senior Process Engineer leverages data analysis, troubleshooting, and process control strategies to improve operational performance and support long-term business objectives.
The Senior Process Engineer serves as the technical leader and process owner for Sustana's recycled fiber manufacturing operations, providing expertise across the production process from wastepaper receiving through finished product manufacturing. This role is responsible for optimizing safety, quality, throughput, reliability, and cost performance while driving continuous improvement initiatives, process standardization, automation enhancements, and capital projects. Working closely with Operations, Maintenance and EHS departments, the Senior Process Engineer leverages data analysis, troubleshooting, and process control strategies to improve operational performance and support long-term business objectives.
- Serve as the technical process owner for recycled fiber manufacturing operations.
- Establish and maintain process centerlines, operating standards, and critical process parameters.
- Optimize throughput, yield, quality, reliability, and overall equipment effectiveness (OEE).
- Identify process bottlenecks and implement sustainable solutions to improve plant performance.
- Develop, execute, and standardize process improvement initiatives and production trials.
- Monitor and improve key performance indicators related to productivity, quality, downtime, and cost.
- Lead process troubleshooting, root cause investigations, and corrective action implementation.
- Analyze process variation and quality performance to improve on-grade production and reduce waste.
- Utilize Lean Manufacturing, Six Sigma, RCA, 5-Why, and other continuous improvement methodologies.
- Develop troubleshooting guides, operating procedures, and best practices to improve consistency and operational discipline.
- Support supplier quality investigations and raw material optimization efforts.
- Analyze process and downtime data to identify trends and operational improvement opportunities.
- Develop and maintain process dashboards, KPIs, and performance reporting tools.
- Partner with Operations and Maintenance team to optimize PLC, DCS, instrumentation, and automation systems.
- Support control strategy development, instrumentation upgrades, and automation projects to improve process stability and efficiency.
- Maintain process control documentation and support technology improvements throughout the facility.
- Work closely with Operations and Maintenance teams to drive equipment and process performance.
- Support predictive and preventive maintenance initiatives through process expertise and equipment analysis.
- Participate in startup, commissioning, shutdown planning, and equipment modification projects.
- Identify, evaluate, and support capital improvement opportunities from concept through implementation.
- Collaborate with cross-functional teams and external vendors to implement new technologies and process improvements.
- Promote a culture of safety, environmental responsibility, and operational excellence.
- Improve fiber, chemical, energy, water, and conversion costs through process optimization.
- Develop business cases, ROI analyses, and capital justifications for improvement projects.
- Ensure process improvements align with safety requirements, environmental permits, and regulatory obligations.
- Participate in Management of Change (MOC), risk assessments, incident investigations, and environmental improvement initiatives.
- Support improvements related to wastewater, sludge, fiber loss, chemical handling, water consumption and emissions.
- Develop and maintain SOPs, operating procedures, centerline documentation, and technical standards.
- Train and mentor operators, supervisors, engineers, and technical personnel.
- Support knowledge transfer and technical capability development throughout the organization.
- Provide leadership and technical guidance on process, automation, and manufacturing best practices.
- Bachelor's Degree in Chemical Engineering, Paper Science, Paper Engineering, or a related discipline.
- Minimum 7-10 years of process engineering experience in pulp and paper, recycled fiber, or other continuous-process manufacturing environments.
- Demonstrated success improving manufacturing KPIs including throughput, quality, yield, reliability, and cost performance.
- Experience leading complex technical investigations, process improvements, and capital projects within a 24/7 manufacturing environment.
- Experience with PLC, DCS, HMI, SCADA, industrial instrumentation, VFDs, and process control systems.
- Familiarity with recycled fiber processing, deinking systems, pulp preparation, or paper manufacturing.
- Experience leading cross-functional teams and implementing automation or continuous improvement initiatives.
- Proficiency with Microsoft Office, statistical software and data historians.
- Lean Manufacturing and/or Six Sigma certification.
- Experience with Rockwell Studio 5000 PLC Logic and Novaspec Delta V DCS system.
- Knowledge of Hydraulics schematics and troubleshooting.
- Strong technical understanding of manufacturing processes and process optimization principles.
- Advanced analytical, troubleshooting, and problem-solving skills.
- Knowledge of process controls, industrial automation, instrumentation, and data analysis.
- Strong communication, leadership, and project management capabilities.
- Ability to influence and collaborate effectively across Operations, Maintenance, Engineering, and Leadership teams.
- Demonstrated effectiveness in collaborating with internal teams, customers, and external vendors to support operational, technical, and business objectives.
- Manufacturing environment, including production, maintenance, and wastewater treatment areas.
- Ability to walk production floors, climb stairs, wear required PPE, and work in varying environmental conditions.
- Occasional off-hours support for emergency response, regulatory matters, or incident investigations.
- 401(k) with employer match
- Health, dental & vision insurance
- Employee assistance program
- Health savings account
- Vacation & Personal Days
- Tuition reimbursement
- Life insurance
- Short & Long Term disability insurance
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