Process Engineer

The Process Engineer is a hands-on engineering role responsible for supporting process development, equipment operation, sample production, troubleshooting, and continuous improvement activities within the Innovation Center (R&D Laboratory). This position serves as a primary technical resource for operating and optimizing pilot-scale and laboratory equipment used in the development of molded fiber products, materials, coatings, and manufacturing processes. 

The PE is responsible for planning and executing development trials, producing customer and internal samples, collecting and analyzing process data, and troubleshooting process, material, and equipment-related issues. This individual works closely with Product Development, Operations, Quality, Maintenance, Sales, and external partners to evaluate new technologies, develop scalable manufacturing solutions, and support commercialization efforts. 

In addition to Innovation Center responsibilities, the PE will periodically support manufacturing operations through process optimization, production troubleshooting, continuous improvement initiatives, plant trials, and new product introductions. This role plays a critical part in bridging research and development activities with commercial manufacturing operations to ensure successful implementation of new products and technologies. 

Success in this position requires a strong combination of engineering fundamentals, mechanical aptitude, hands-on equipment experience, analytical problem-solving skills, and a willingness to work directly with both laboratory and production personnel. 

Essential Job Duties & Responsibilities: 

A Process Engineer will be expected to demonstrate strength in the following areas as part of their role: 

Innovation Center Operations & Sample Production 

• Operate, troubleshoot, optimize, and maintain pilot-scale and laboratory process equipment. 

• Produce customer, internal, and development samples in support of product development projects and commercial opportunities. 

• Plan, coordinate, and execute laboratory and pilot-scale trials. 

• Support rapid prototyping efforts for new molded fiber products and process technologies. 

• Maintain safe and efficient operation of Innovation Center equipment and work areas. 

• Assist in the development of processing parameters for new products, materials, coatings, and manufacturing technologies. 

• Record, analyze, and document trial conditions, process parameters, observations, and test results. 

• Prepare technical reports and summaries of trial findings and recommendations. 

• Coordinate sample production schedules to support product development timelines and customer requests. 

• Assist with Innovation Center equipment setup, changeovers, cleaning, calibration, and maintenance activities. 

• Support laboratory organization, inventory management, and material handling activities. 

Equipment Operation & Troubleshooting 

• Serve as a primary operator for pilot plant and laboratory equipment including stock preparation, forming, pressing, drying, trimming, coating, testing, and related process systems. 

• Troubleshoot equipment, process, material, and quality issues affecting development projects and sample production. 

• Identify root causes of process variation and implement corrective actions. 

• Monitor equipment performance and recommend improvements that increase reliability, efficiency, and safety. 

• Assist with installation, startup, commissioning, and qualification of new Innovation Center equipment. 

• Develop and maintain operating procedures, setup instructions, and troubleshooting guides. 

• Support preventive maintenance efforts and collaborate with Maintenance to improve equipment uptime. 

• Evaluate equipment capability and recommend modifications or upgrades to improve process performance. 

  Process Development & Experimental Support 

• Assist in the development of new manufacturing processes, materials, products, and coatings. 

• Support Design of Experiments (DOE) activities and process optimization projects. 

• Collect and analyze process, quality, and equipment performance data. 

• Identify critical process parameters and establish recommended operating conditions. 

• Develop process centerlines and operating standards for Innovation Center equipment. 

• Participate in material qualification and validation activities. 

• Support product and process scale-up activities from laboratory trials to commercial manufacturing. 

• Document findings and communicate recommendations to technical and business stakeholders. 

  Manufacturing & Operations Support 

• Provide engineering support to manufacturing facilities as business needs require. 

• Assist Operations and Production teams in troubleshooting process, quality, material, and equipment-related issues. 

• Participate in root cause investigations and implementation of corrective actions. 

• Analyze manufacturing data to identify opportunities to improve safety, quality, throughput, yield, and cost. 

• Support continuous improvement initiatives utilizing Lean Manufacturing, Six Sigma, and problem-solving methodologies. 

• Assist with process validation, startup activities, and qualification of new products and processes. 

• Support plant trials involving new products, materials, tooling, coatings, and manufacturing technologies. 

• Work closely with Production, Maintenance, Quality, and Product Development teams to commercialize Innovation Center developments. 

• Assist in monitoring and improving manufacturing performance metrics including OEE, scrap, yield, throughput, and process capability. 

• Serve as a technical resource to operators, supervisors, and maintenance personnel during troubleshooting and improvement activities. 

Qualifications

Knowledge, Skills, & Abilities: 

• Comply with Safety and GMP. 

• General use of Microsoft office suite, including Word, Excel, and PowerPoint 

• Develop and write Standard Operating Procedures or Work Instructions as needed. 

• Present for the local plant leadership team and/or peers. 

• Document and track process changes to better understand the impacts of changes and the importance of Centerlines. 

• Independent troubleshooting skills. 

• The ability to work independently on projects on an as-needed basis. 

• Strong Communication Skills. 

• Detail oriented with the ability to multitask. 

• Must have a positive attitude towards teamwork and continuous process improvement. 

  Technical Skills 

• Understanding of process engineering fundamentals and manufacturing operations. 

• Knowledge of fluid systems, pumps, valves, vacuum systems, pneumatic systems, hydraulic systems, and process controls. 

• Ability to read and interpret engineering drawings, schematics, P&IDs, and technical specifications. 

• Familiarity with experimental design and statistical problem-solving techniques. 

• Proficiency with Microsoft Office and data analysis tools. 

  Equipment & Troubleshooting Skills 

• Ability to independently operate laboratory and pilot-scale manufacturing equipment. 

• Strong mechanical troubleshooting capability. 

• Ability to identify and resolve equipment performance, reliability, and process-related issues. 

• Experience diagnosing product quality defects and process variation. 

• Ability to troubleshoot material handling, forming, pressing, drying, trimming, and coating processes. 

  Professional Skills 

• Strong verbal and written communication skills. 

• Excellent analytical and organizational skills. 

• Ability to manage multiple projects and priorities simultaneously. 

• Ability to work independently and within cross-functional teams. 

• Strong attention to detail and commitment to continuous improvement. 

• Self-motivated with a hands-on, proactive approach to problem solving. 

Education and experience: 

Required 

• Bachelor's degree in Chemical Engineering, Mechanical Engineering, Manufacturing Engineering, Paper Science, Industrial Engineering, or related technical discipline. 

• 1-3 years of engineering experience in manufacturing, process engineering, R&D, pilot plant, or industrial environment. 

• Strong mechanical aptitude and problem-solving skills. 

• Ability to work safely in both laboratory and manufacturing environments. 

  Preferred 

• Experience operating pilot-scale, laboratory, or manufacturing process equipment. 

• Experience in molded fiber, pulp and paper, packaging, converting, plastics, nonwovens, or related process industries. 

• Experience supporting product development, process development, or commercialization projects. 

• Experience with equipment troubleshooting and root cause analysis. 

• Familiarity with Lean Manufacturing, Six Sigma, statistical analysis, and process capability concepts. 

• Experience producing prototype or customer evaluation samples. 

• Experience supporting technology transfer from laboratory or pilot environments into commercial manufacturing. 

Physical requirements: 

• Ability to work in both office and industrial environments.  

• Ability to stand, walk, bend, climb, and move throughout laboratory and manufacturing facilities.  

• Ability to lift up to 50 pounds occasionally.  

• Ability to use personal protective equipment as required.  

• Ability to travel periodically between company facilities, suppliers, customer locations, and industry events. 

Key success factors: 

A successful candidate will: 

• Be comfortable operating and troubleshooting equipment directly rather than serving solely in an analytical role. 

• Take ownership of Innovation Center operations and sample production activities. 

• Effectively translate laboratory and pilot-scale learnings into scalable manufacturing solutions. 

• Collaborate successfully with Product Development, Sales, Quality, Operations, and Maintenance teams. 

• Drive continuous improvement through data-driven problem solving and hands-on experimentation. 

• Demonstrate the flexibility to balance Innovation Center responsibilities with occasional manufacturing support needs. 

• Serve as a key contributor in advancing new molded fiber technologies from concept through successful commercial implementation. 

Disclaimer 

The above statements are intended to describe the general nature and level of work being performed by people assigned to this classification. They are not to be construed as an exhaustive list of all responsibilities, duties, and skills required of personnel so classified. All personnel may be required to perform duties outside of their normal responsibilities from time to time, as needed.