Senior Process Engineer

3 weeks ago

saint paul, United States Bell International Laboratories Full time

Position Overview

The Senior Process Engineer will be responsible for leading the development, optimization, and scale-up of manufacturing processes for personal care and Over-the-Counter (OTC) products, with a focus on sunscreens and skincare formulations. The role requires a strong technical background in chemical engineering, process design, and continuous improvement to ensure the efficient, safe, and high-quality production of a diverse range of products. The successful candidate will work cross-functionally with R&D, Quality, and Production teams to support new product introductions, resolve process challenges, and drive process innovation.

Key Responsibilities

  • Process Development & Optimization:
  • Design, develop, and optimize scalable manufacturing processes for personal care and OTC products, ensuring compliance with cGMP and FDA regulations.
  • Develop robust process documentation including Process Flow Diagrams (PFDs), Standard Operating Procedures (SOPs), and Work Instructions.
  • Evaluate and optimize mixing, blending, emulsification, and filling processes for a variety of skincare and sunscreen formulations.
  • New Product Introduction (NPI):
  • Collaborate closely with R&D teams to ensure seamless scale-up from bench-scale to full-scale production.
  • Conduct process trials, validation runs, and pilot batches to establish reliable manufacturing processes for new formulations.
  • Lead the technical transfer of new products to production and provide technical support for troubleshooting.
  • Process Improvement:
  • Identify opportunities for process improvements to enhance efficiency, yield, and product quality while reducing costs.
  • Utilize Lean Manufacturing, Six Sigma, and other problem-solving methodologies to identify root causes and implement corrective actions.
  • Implement automation and control strategies to enhance process capability and reduce variability.
  • Project Management:
  • Lead and manage multiple engineering projects simultaneously, ensuring on-time and within-budget completion.
  • Prepare and present technical reports, project updates, and process performance metrics to senior management.
  • Compliance & Quality:
  • Ensure processes comply with regulatory requirements (e.g., FDA, OTC monographs) and internal quality standards.
  • Support quality assurance initiatives by conducting risk assessments, participating in audits, and implementing corrective actions as necessary.
  • Equipment & Facility Support:
  • Provide engineering support for the selection, installation, and qualification of manufacturing equipment.
  • Oversee the development and maintenance of process control systems and work with the maintenance team to ensure optimal equipment performance.

Qualifications

  • Bachelor’s Degree in Chemical Engineering, Mechanical Engineering, or a related field. Master’s Degree preferred.
  • Minimum of 7+ years of experience in process engineering, with at least 3 years in personal care, skincare, or OTC manufacturing.
  • Expertise in formulation and manufacturing of sunscreens and skincare products is highly desirable.
  • Strong knowledge of cGMP, FDA regulations, and OTC compliance standards.
  • Demonstrated experience in process scale-up, equipment selection, and process troubleshooting.
  • Lean Six Sigma certification (Green Belt or higher) is a plus.

Skills & Competencies

  • Excellent problem-solving and analytical skills with a strong attention to detail.
  • Strong project management and organizational skills, with the ability to manage multiple priorities.
  • Effective communication and interpersonal skills for cross-functional collaboration.
  • Ability to work independently as well as in a team-oriented environment.

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