Senior Process Engineer

About the Role

The Senior Process Engineer is 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. This role requires expertise in chemical engineering, process design, and continuous improvement to ensure efficient, safe, and high-quality production. The position collaborates cross-functionally with R&D, Quality, and Production teams to support new product introductions, resolve process challenges, and drive innovation.

Responsibilities

• Collaborate with R&D to scale up processes from bench-scale to full-scale production.
• Conduct process trials, validation runs, and pilot batches for new formulations.
• Lead technical transfer of new products and provide troubleshooting support.
• Identify and implement process improvements to enhance efficiency, yield, and product quality.
• Utilize Lean Manufacturing and Six Sigma methodologies for problem-solving and corrective actions.
• Implement automation and control strategies to reduce variability.
• Manage multiple engineering projects, ensuring timely and budget-conscious completion.
• Prepare and present technical reports and process performance metrics.
• Ensure regulatory compliance with FDA, OTC monographs, and internal quality standards.
• Support quality assurance through risk assessments, audits, and corrective actions.
• Provide engineering support for equipment selection, installation, and qualification.
• Oversee process control systems and collaborate with maintenance teams for equipment performance.

Qualifications

• 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.
• Proficiency in Microsoft Office.
• Strong technical and regulatory expertise.
• Experience in technical transfer projects and process troubleshooting.
• Excellent communication, problem-solving, and critical-thinking skills.
• Ability to manage multiple responsibilities and work cross-functionally.
• Demonstrated leadership skills.

Desired Qualifications

• Masters degree preferred.
• Expertise in sunscreen and skincare formulation manufacturing.
• Experience in process scale-up and equipment selection.
• Lean Six Sigma certification (Green Belt or higher).
• Fluency in Spanish is a plus.