Compounder Process Engineer - 1st Shift

Description / Scope / Mission

The Compounding Process Engineer focuses on the design, optimization, and implementation of manufacturing processes for liquid domestic and consumer products. This role bridges the gap between R&D formulation and full-scale commercial manufacturing, ensuring that production processes are safe, efficient, robust, and capable of consistently meeting quality standards.

Key Responsibilities/ Accountabilities

• Analyze existing compounding processes to identify inefficiencies, bottlenecks, and waste.
• Implement Lean Manufacturing and Six Sigma methodologies to improve yield and cycle times.
• Establish, validate, and document standard operating parameters (e.g., optimal viscosity, temperature ranges, shear rates) for batch processing.
• Partner with Customers and R&D to transition new formulations from bench/pilot scale to mass production plants.
• Determine the appropriate blending equipment, agitator types, and raw material addition sequences required to maintain product integrity at commercial scale.
• Lead and document pilot runs and first-production batches, troubleshooting any deviations in product texture, stability, or separation.
• Assist in the specification, sourcing, installation, and commissioning of new manufacturing equipment, such as mixing and storage tanks, automated dosing systems, high-shear mixers, and Clean-in-Place (CIP) units.
• Author and execute Installation Qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ) protocols for new and modified equipment in partnership with Validation engineer and Quality Manager.
• Partner with Controls/Automation Engineers to optimize PLC sequences, batching software recipes, and inline instrumentation (flow meters, load cells, pH probes).
• Serve as the technical lead for investigating batch failures, out-of-specification (OOS) incidents, or systemic process deviations, implementing sustainable engineering solutions (CAPA).
• Design and validate CIP (Clean-in-Place) and SIP (Sanitization-in-Place) cycles to minimize water and chemical consumption while ensuring zero cross-contamination.
• Ensure all process designs comply with environmental, health, and safety regulations (OSHA; FDA; DNR, etc.), incorporating proper venting, spill containment, and safe chemical handling features.

Education / Certification / Qualifications / Experience

• BA/BS degree in a field of science required or equivalent experience.
• Background with cGMP and FDA compliance preferred.
• Demonstration of strong detail orientation, organizational skills and the ability to work independently and multi-task.
• Proficient with Process Flow Diagrams (PFDs), Piping and Instrumentation diagrams (P&IDs) and CAD software.
• Experience: Minimum of 2 years as process or manufacturing engineer. Direct experience with liquid consumer products is preferred.

Specific Knowledge

• Fluid mechanics, rheology, compounding equipment

Tools/Equipment Used

• Variety of hand tools, computer, telephone, copier and fax.

Work Environment/PPE Required

• Exposure to wet, humid conditions (non-weather); exposure to chemical manufacturing environment; exposure to outdoor weather conditions; vibration; and work/job related travel up to 1/3 of the time.
• Work near moving mechanical parts 1/3 to 2/3 of the time.
• Exposure to moderate noise.
• Wear PPE as required, not limited to safety glasses, steel toed shoes, etc.