Senior Process Engineer

Description

Position Summary:

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.

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.

Requirements

Required Skills/Abilities:

• Working knowledge or background in chemical manufacturing industry
• Strong technical and/or regulatory expertise
• Detailed record keeping and communication of results to others
• Project skills appropriate for leadership of tech transfer projects
• Excellent written, verbal and interpersonal communication skills
• High level of initiative, innovation, critical thinking and problem-solving skills
• Ability to work cross-functionally & at all levels within the organization including senior leadership
• Ability to prioritize multiple responsibilities and manage deadlines accordingly
• Communicate effectively and professionally both internally and externally
• Exceptional attention to detail and high level of accuracy & organization
• Ability to work as part of a team and excel independently in fast-paced environment
• Ability to adapt quickly to changing circumstances
• Demonstrated leadership skills
• Proficient with Microsoft Office

Required Education and Experience:

• Bachelor’s degree in Chemical Engineering, Mechanical Engineering, or a related field.
• Minimum of 7 years of experience in process engineering, with at least 3 years in personal care, skincare, or OTC manufacturing.
• Strong knowledge of cGMP, FDA regulations, and OTC compliance standards.

Preferred Education and Experience:

• Master’s Degree preferred.
• Expertise in formulation and manufacturing of sunscreens and skincare products is highly desirable.
• Demonstrated experience in process scale-up, equipment selection, and process troubleshooting.
• Lean Six Sigma certification (Green Belt or higher) is a plus.
• Fluent in Spanish is a plus.

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

EEO Statement

Bell International Laboratories provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.

This policy applies to all terms and conditions of employment, including recruiting, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence, compensation and training.

Salary : $100,000 - $140,000