Senior Process Engineer

Sustana Group; De Pere (WI); On-site; USD 110,000 - 160,000; Full time

Job summary

Sustana Group seeks a Senior Process Engineer to lead technical process ownership across recycled fiber manufacturing, from wastepaper intake to finished product. You will drive safety, quality, throughput, reliability and cost performance while leading CI initiatives, standardization, and automation enhancements.

You will partner with Operations, Maintenance and EHS to use data analysis, troubleshooting, and control strategies to elevate performance and support long-term business objectives.

Qualifications

• Bachelor's degree in Chemical Engineering or related discipline.
• 7–10 years of process engineering in pulp and paper, recycled fiber, or similar manufacturing environment.
• Experience leading technical investigations, process improvements, and capital projects.

Responsibilities

• 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 OEE.
• Lead troubleshooting, root-cause investigations, and corrective actions.
• Support predictive and preventive maintenance through process expertise.

Education

Bachelor's Degree in Chemical Engineering, Paper Science, Paper Engineering, or a related discipline

Tools

Rockwell Studio 5000 PLC Logic

Novaspec DeltaV DCS

PLC/SCADA instrumentation

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.

Key Responsibilities

Process Ownership & Optimization

• 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.

Process Control, Automation & Data Analytics

• 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.

Operations, Reliability & Capital Projects

• 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.

Cost, Safety & Environmental Stewardship

• 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.

Training & Technical Leadership

• 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.

Qualifications

Education & Experience

• 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.

Preferred Qualifications

• 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.

Knowledge, Skills & Abilities

• 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.

Physical Requirements and Working environment

• 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.