Senior Process Engineer

Balchem; Minnesota; On-site; USD 120,000 - 145,000; Full time

Job summary

Balchem is seeking a Senior Process Engineer in Extrusion Technology to translate product concepts into scalable manufacturing processes within Human Nutrition and Health R&D. The role collaborates with Product Development, Manufacturing, Quality and Regulatory to de-risk scale-up and enable successful commercialization.

You will lead twin screw extrusion projects, optimize process parameters, and guide technology transfer from lab to full-scale production, while ensuring GMP and safety

Qualifications

• Bachelor's degree in Chemical Engineering, Food Engineering, Mechanical Engineering, Food Science or related field.
• Minimum seven years of experience in process engineering or extrusion technology incl. scaling to manufacturing.
• Expertise in twin screw extrusion and materials/formulation relationship.
• Knowledge of GMP, HACCP, quality systems and change management.

Responsibilities

• Lead design and scale-up of extrusion processes for commercial manufacturing.
• Drive technology transfer and process qualification for new products.
• Collaborate with Product Development, Manufacturing, Quality, Regulatory teams.
• Perform root cause analysis and optimize processes.

Skills

extrusion technology

twin screw extrusion

process development

scale-up / tech transfer

data analysis

project management

communication / leadership

cross functional collaboration

statistical analysis

GMP knowledge

Education

Bachelor's degree in Chemical Engineering

Advanced degree preferred

Related technical field acceptable

Tools

Twin screw extrusion equipment

Laboratory pilot equipment

Process instrumentation

Job description

COMPANY OVERVIEW

Balchem is committed to making the world a healthier place by delivering trusted innovative and science based solutions for the health and nutritional needs of the world Balchem employs approximately 1400 employees worldwide who provide the service quality and technology that enables our customers to win with their customers We have built a reputation for delivering results to all of our stakeholders Founded in 1967 Balchem a Maryland corporation became a publicly traded company in 1970 and is listed on Nasdaq under the symbol BCPC Our corporate headquarters is located in Montvale New Jersey and we have a broad network of sales offices manufacturing sites and R&D centers primarily located in the US and Europe The Company consists of three business segments Human Nutrition and Health Animal Nutrition and Health and Specialty Products

POSITION SUMMARY

The Senior Process Engineer Extrusion Technology is a senior level individual contributor within the Human Nutrition & Health R&D Process Technology organization The Process Technology team serves as the technical bridge between Product Development and Manufacturing helping translate product concepts into scalable robust and economically viable manufacturing processes while maintaining product integrity This role brings deep expertise in extrusion technology to process development scale up commercialization technology transfer manufacturing implementation and lifecycle optimization The position works closely with Product Development Manufacturing Engineering Quality Supply Chain EHS and Commercial teams as applicable to reduce technical risk establish scalable operating conditions and support sustainable commercial processes While primarily focused on HNH and extrusion technology the role may contribute to adjacent processing technologies and other Process Technology needs across Balchem where its expertise is applicable

ESSENTIAL FUNCTIONS

Innovation Scale Up and Manufacturability Lead safe and compliant process development activities aligned with quality food safety environmental and regulatory requirementsPartner with Product Development to evaluate manufacturability identify process risks and develop scalable manufacturing solutions while preserving the intended product design functionality and performanceDesign execute and analyze laboratory pilot and commercial scale trials to de risk scale up establish process capability and support commercialization decisionsEstablish process requirements operating conditions and technical success criteria to guide scale up and commercialization decisionsCommercialization and Technology Transfer Lead or support commercialization process qualification and technology transfer activities for new products and process changesTranslate development knowledge into manufacturing requirements process controls operating windows and specifications Assess manufacturing readiness resolve technical gaps and support startup and initial production activitiesEnsure effective transfer of technical knowledge process risks and operating guidance to manufacturing teamsDevelop or support qualification plans acceptance criteria technical protocols and final reports that document process readiness results and residual riskExtrusion Technology Expertise Serve as a technical subject matter expert for extrusion technologies particularly twin screw extrusionApply extrusion expertise to process development scale up equipment evaluation manufacturing support and commercializationDevelop and optimize process parameters equipment configurations control strategies and operating windowsLead complex technical investigations involving extrusion equipment raw materials process performance and product qualityContribute to capability development through standards training best practices and evaluation of emerging technologiesManufacturing Support and Process Optimization Partner with Manufacturing to improve process safety quality reliability efficiency and capacity utilizationLead or support technical investigations and root cause analysis and partner with Manufacturing and other accountable functions to define and implement corrective actions and process improvements Analyze process data to identify variation process limitations and improvement opportunitiesSupport lifecycle activities including process optimization raw material qualification change management and cost improvement initiativesBroader Process Technology Contribution Contribute engineering expertise to projects involving adjacent technologies including spray drying agglomeration encapsulation blending drying material handling and powder processingSupport cross functional projects requiring integrated process solutions across multiple technologiesShare technical knowledge engineering methods and lessons learned to strengthen overall Process Technology capabilitiesEngineering and Cross Functional Collaboration Collaborate with Engineering on equipment selection process design capital projects commissioning and startup activitiesPartner with Quality Regulatory Supply Chain Manufacturing EHS and Commercial teams to ensure successful commercialization and process implementationProvide technical input for equipment specifications manufacturing requirements and investment decisionsClearly communicate technical risks recommendations and decisions to both technical and nontechnical stakeholdersTechnical Leadership and Documentation Manage assigned technical projects and balance priorities across development commercialization and manufacturing support activitiesApply sound experimental design statistical analysis and engineering judgment to support decision makingDevelop and maintain technical reports specifications SOPs process documentation and best practicesPresent technical findings mentor team members and contribute to organizational capability developmentPerform other duties as assigned

REQUIREMENTS

Bachelors degree in Chemical Engineering Food Engineering Mechanical Engineering Food Science or related technical field required; advanced degree preferredCandidates with a non engineering technical degree must demonstrate substantial applied process engineering and commercial scale up experienceMinimum seven years of relevant experience in process engineering process development or extrusion technology including demonstrated experience scaling and transferring products or processes from laboratory or pilot environments into commercial manufacturingDemonstrated expertise in extrusion preferably with twin screw extrusion and the relationship between materials formulation equipment process conditions and product performanceStrong understanding of process engineering fundamentals including heat transfer mass transfer fluid flow drying rheology material handling and process controlExperience designing trials analyzing data establishing process parameters and troubleshooting manufacturing processesWorking knowledge of one or more adjacent processing technologies such as spray drying agglomeration encapsulation powder processing blending or material handling preferredKnowledge of GMP HACCP food safety quality systems regulatory requirements and change management processesStrong technical communication presentation leadership and project management skills with the ability to influence across functionsAbility to manage multiple priorities and travel as required to support pilot trials manufacturing activities and commercialization effortsIND123 The expected salary range for this position is 120000 145000 a year