Senior Process Engineer

Position Overview

A variety of soft skills and experience may be required for the following role Please ensure you check the overview below carefully.

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.

Physical Demands

• Must be able to lift up to 20 pounds on a regular basis.
• Ability to wear Personal Protective Equipment including a respirator, glove, and eye protection.
• Ability to perform work in a manufacturing environment where there is exposure to occupational hazards.

Job Type : Full-time

Schedule :

• Monday to Friday
• No weekends

Work Location : In person

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