Senior Process Engineer

About the role

HydroGraph is a hyper‑growth advanced materials company scaling pristine, high‑performance graphene via its patented Hyperion detonation technology. With more than 70 active commercial projects and a global footprint, HydroGraph builds next‑generation engineered materials for coatings, composites, and energy storage. The Sr. Process Engineer joins the Advance Manufacturing team to connect material properties, process behavior, and testing requirements, ensuring new products and process changes are ready for production. This role leads critical process parameter definition, testing standards, and change‑control decisions while mentoring less‑experienced engineers and contributing to mechanical system design and selection.

Responsibilities

• Develop and approve standards, processes, test plans, and documentation to ensure seamless new product introductions to production.
• Identify critical process parameters and operating limits; gather and analyze data to support decisions and recommend or approve production parameters.
• Manage change‑control requests, analyzing data to determine implementation decisions and required testing levels.
• Ensure technical completeness and readiness of FMEAs, DFMs, and RCFAs.
• Provide hands‑on support and ideas that advance the goals of Advance Manufacturing and the broader organization.
• Support training and production readiness for new product launches, including training production technicians and operators.
• Participate in design and development of new products, processes, and equipment design/selection.
• Serve as a technical resource and mentor to Process Engineers and other team members.
• Collaborate cross‑functionally with R&D, Manufacturing, Quality, and other functions to ensure testing and material requirements are understood and met.

Requirements

• 10+ years of experience in process engineering or a related field.
• Previous experience in New Product Introduction (NPI) is required.
• Demonstrated experience developing and approving process standards, test plans, and acceptance criteria.
• Experience identifying critical process parameters and operating limits, using data to guide production decisions.
• Strong analytical and data‑driven decision‑making skills.
• Ability to work cross‑functionally and communicate effectively with Manufacturing, R&D, Quality, and other teams.
• Experience mentoring or supporting less experienced engineers.
• Knowledge of Statistical Process Control (SPC), Design of Experiments (DOE), and Lean Manufacturing.
• Strong knowledge of statistical analysis.
• Preferred: Bachelor’s degree in Engineering, Materials Science, or Chemistry.
• Preferred: Background in chemical processing, material development, or related industry (e.g., food production).
• Preferred: Green or Black Belt certification.
• Preferred: Experience with Visio or similar process‑mapping/documentation tools.

Skills

• Leadership and team motivation
• Accountability and ownership mindset
• Strategic thinking and business acumen
• Stakeholder management and relationship building
• Conflict resolution and negotiation
• Adaptability and flexibility in dynamic environments
• Decision‑making under uncertainty
• Attention to detail and quality focus
• Customer service orientation
• Emotional intelligence and active listening
• Critical thinking and creative problem‑solving

Work Environment

This role operates in an active chemical/process manufacturing environment with regular presence on the plant floor. The engineer will be exposed to industrial equipment, chemical agents, and process systems, and must adhere to all applicable safety protocols. The environment includes indoor and outdoor process/chemical plant settings with exposure to heat, noise, fumes, and moving machinery. Occasional outdoor work in varying weather conditions is required to operate valves and manage chemical feedstock supply lines.

Physical requirements: standing and walking for extended periods; frequent lifting and carrying of equipment, tools, or materials up to 20 lb (occasional lifting up to 50 lb with assistance); occasional work at elevations up to 15 ft using ladders, platforms, scissor lifts, or elevated walkways. Mandatory personal protective equipment (PPE) includes safety glasses, hard hat, steel‑toed boots, hearing protection, respiratory protection when needed, and fall‑protection equipment for elevated work.

Schedule

Standard business hours, Monday through Friday. Occasional weekend or off‑hours work may be required to support planned maintenance, shutdowns, startups, or urgent production challenges. May require occasional travel to other production facilities, client locations, or vendor facilities.