Process Development Engineer

Job purpose:

The Process Engineer continuously evaluates all dairy processing equipment (CIP systems, membranes filtration systems, HTST's, separators, milk receiving systems, batching systems, & VTIS/UHT operations) in our facilities, for reliability and effectiveness tracking and documenting areas of success as well as driving assigned opportunities for improvement and growth. In fulfilling this role, the Process Development Engineer works cross-functionally with commercial, manufacturing, engineering, IT, quality, R&D, and other functions within fairlife. They will be the top liaison for procuring new processing equipment while incorporating our learnings with new technologies and processes to improve quality, efficiencies, and speed to market.

Responsibilities:

With a focus on continuous improvement and innovation this role is responsible for:

• Defining the objectives of capacity expansion projects and overseeing the process design from milk receiving to filling of bottles to achieve lowest risk design at lowest total cost of ownership,
• Developing or assisting with design basis for new line/plant expansions (mass balance, energy balances, SKU mix, process flow diagram, PID approval),
• Assisting in the development and commercialization of new technologies and processes to improve product quality, process efficiencies, and speed to market for delivery of products,
• Reviewing and updating functional specifications related to new processing equipment,
• Reviewing new and existing line/plant designs with focus in milk processing area to reduce food safety risk and improve the overall efficiency and cost of operations,
• Solving complex processing problems following escalation from plants; managing the process of escalation with plants to ensure timely resolution,
• Continuously developing systems for monitoring milk production process and situational awareness to enhance efficiencies, reduce losses and minimize total cost of ownership. Examples include design for extended run time, faster CIP turnaround, prediction of next CIP, energy recovery, water re-use, chemical re-use etc.,
• Defining standards to improve accuracy and efficiency of new and existing equipment,
• Supporting commissioning and validation activities, review of Factory Acceptance Test and Site Acceptance Test (FAT/SAT) protocols and execution of acceptance tests,
• Assure plant compliance with Federal, State and Corporate environmental laws, rules & regulations,
• Ensuring that the processes comply with U.S. Food and Drug Administration (FDA) regulations, PMO, other regulatory requirements, Company policies, operating procedures, processes, and task assignments,
• Effectively collaborating and coordinating with plant & project engineering teams to ensure all assigned project work is completed on time and within budget,
• Documenting and clearly communicating the design intent of all new and existing plant equipment to the plants' key stakeholders,
• Providing verbal and written reports to communicate project status as required and contributing to project review meetings,
• Playing a key role in supporting the organization for the commercialization of new products,
• key decision maker in aseptic equipment vendor selection and contract negotiations,
• Developing relationships globally in the dairy processing industry to keep abreast of best-in-class performance of various designs,
• Other duties as assigned.

Skills/qualifications required:

• 3+ years of progressive leadership experience in engineering and operations disciplines, background in low acid aseptic beverage preferred,
• Bachelor's degree in engineering: chemical, mechanical, process or agricultural. Advanced degrees or other professional certifications preferred but not required,
• Proven track record of improving manufacturing processes through re-design and automation, and the introduction of new technologies,
• Strong working knowledge of automation, PLC, MES and factory floor monitoring and reporting,
• Strong attention to detail and analytical skills.
• Data analysis and Process modeling in Microsoft Excel is required,
• Process modeling using software's such as Aspen, SuperPro or others will be a value addition,
• Strong understanding of process/product interactions with the ability to provide comprehensive reports on risk assessment and primary recommendations,
• Demonstrated excellence in communication and presentation,
• Familiarity with instrumentation (flow meters, level transmitters, RTDs/temperature transmitters, level probes, etc.),
• Ability to handle ambiguity and thrive in a fast paced, entrepreneurial work environment,
• Ability to travel as needed,
• Apart from the technical skills, this position will require a sense of purpose in your work, a sense of urgency in dealing with issues, innovative problem-solving skills, a desire to constantly learn and above all a 'One Team' mind set to work through challenges.

Food safety requirements:

• Notify management of any repairs or adjustments that are required that may affect product quality or food safety.
• Perform all duties necessary to meet Company, Customer and/or Government requirements/standards as prioritized by the Company.
• Ability to initiate action to prevent the occurrence of nonconformities relating to Food Safety and the Quality of the product, processes, quality system, or safety system.
• Identify and record any problems relating to Food Safety and the Quality of the ingredients, processes, quality system, or safety system.

Position location:Webster, NY

Reports to: Sr. Process Development Engineer

Travel requirements: 50% including some international

Exempt/nonexempt: Exempt