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.