Plant Manager

Company:
Crysalis Bioscience

Location:

Negotiable

Crysalis Biosciences Inc. is seeking a strategic and results‑driven Plant Manager to oversee our ethanol production facility in Sauget, Illinois. The Plant Manager will be responsible for the overall leadership, operation, safety, environmental compliance, and financial performance of an ethanol production plant. This role ensures the facility operates safely, efficiently, and in full compliance with regulatory requirements while meeting production, quality, and cost objectives.

The plant manager will report to the CEO. A key focus for this position will be the successful integration of advanced process technologies—such as Alpha Tech and high‑protein fractionation systems (e.g., PROTOMAX™/APP™)—to transform traditional co‑products (DDGS/WGS) into high‑value specialized products for global markets.

• Direct and manage day‑to‑day ethanol plant operations, including fermentation, distillation, dehydration, solids handling, and co‑product production (DDGS, syrup, corn oil, CO₂, etc.).
• Ensure plant production meets or exceeds volume, yield, and efficiency targets.
• Optimize process performance, minimizing downtime and maximizing throughput.
• Oversee startup, shutdown, and turnaround activities.
• Lead a strong safety‑first culture, ensuring compliance with OSHA, EPA, and state regulatory requirements.
• Ensure adherence to environmental permits (air, water, waste, SPCC, RMP, etc.).
• Champion risk assessments, incident investigations, and corrective action implementation.
• Promote employee engagement in safety programs and continuous improvement.
• Oversee preventive, predictive, and corrective maintenance programs.
• Ensure reliability of critical equipment including boilers, evaporators, centrifuges, dryers, turbines, and fermentation systems.
• Manage capital projects, repairs, and plant upgrades within approved budgets.
• Lead, mentor, and develop department managers, supervisors, and plant staff.
• Foster accountability, teamwork, and continuous learning across all departments.
• Ensure staffing levels, training, and certifications meet operational requirements.
• Conduct performance evaluations and support succession planning.
• Exceptional troubleshooting and critical thinking skills with the ability to lead a 24/7 manufacturing operation.
• Develop and manage the plant operating budget and capital expenditure plans.
• Monitor KPIs related to production costs, yields, energy consumption, and labor efficiency.
• Collaborate with corporate leadership on strategic planning and performance reporting.
• Drive cost‑reduction initiatives without compromising safety or quality.
• Ensure ethanol and co‑products meet quality specifications and customer requirements.
• Oversee compliance with ISO, GMP, HACCP, or other quality systems as applicable.
• Support audits, inspections, and regulatory reviews.
• Lead Lean, Six Sigma, or other continuous improvement initiatives.
• Identify and implement process improvements and innovative technologies.
• Encourage innovation and data‑driven decision‑making.

• Bachelor’s degree in chemical engineering, Mechanical Engineering, Industrial Engineering, or related field (or equivalent industry experience).
• 7–10+ years of experience in industrial manufacturing, with direct ethanol or biofuels experience strongly preferred.
• 10–15 years of experience in ethanol production or similar process manufacturing, with at least 5 years in a senior management/supervisory role.
• Minimum 3–5 years in a plant or operations leadership role.
• Strong knowledge of ethanol production processes, utilities, and co‑products.
• Demonstrated experience managing safety, environmental compliance, and operations teams.
• Proven financial and budgeting experience in a manufacturing environment.

• Ethanol dry mill or wet mill plant experience.
• Experience with OSHA PSM, EPA RMP, and environmental permitting.
• Ability to manage large‑scale Cap Ex projects and technical facility upgrades.
• Strong financial acumen and experience with Profit & Loss management.
• Lean Manufacturing or Six Sigma certification.

• Industrial manufacturing setting.
• Rotating or extended hours as needed.
• On‑call availability for operational issues.

• Insurance:
  Comprehensive Medical, Dental, and Vision plans.
• Retirement: 401(k) with company matching.
• Bonus:
  Performance‑based annual incentive program.
• PTO:
  Generous Vacation/Personal Time Off and Holiday pay.
• Relocation:
  Assistance available for highly qualified candidates.