Senior Process Engineer

COMPANY OVERVIEW:

Balchem is committed to making the world a healthier place by delivering trusted, innovative, and science-based solutions for the health and nutritional needs of the world. Balchem employs approximately 1,400 employees worldwide who provide the service, quality, and technology that enables our customers to win with their customers. We have built a reputation for delivering results to all of our stakeholders.

Founded in 1967, Balchem, a Maryland corporation, became a publicly-traded company in 1970 and is listed on Nasdaq under the symbol BCPC. Our corporate headquarters is located in Montvale, New Jersey, and we have a broad network of sales offices, manufacturing sites, and R&D centers, primarily located in the U.S. and Europe. The Company consists of three business segments:
Human Nutrition and Health, Animal Nutrition and Health, and Specialty Products.

POSITION SUMMARY:

The Senior Process Engineer, Extrusion Technology is a senior-level individual contributor within the Human Nutrition & Health R&D Process Technology organization. The Process Technology team serves as the technical bridge between Product Development and Manufacturing, helping translate product concepts into scalable, robust, and economically viable manufacturing processes while maintaining product integrity.

This role brings deep expertise in extrusion technology to process development, scale-up, commercialization, technology transfer, manufacturing implementation, and lifecycle optimization. The position works closely with Product Development, Manufacturing, Engineering, Quality, Supply Chain, EHS, and Commercial teams, as applicable, to reduce technical risk, establish scalable operating conditions, and support sustainable commercial processes. While primarily focused on HNH and extrusion technology, the role may contribute to adjacent processing technologies and other Process Technology needs across Balchem where its expertise is applicable.

ESSENTIAL FUNCTIONS:

Innovation Scale-Up and Manufacturability Lead safe and compliant process development activities aligned with quality, food safety, environmental, and regulatory requirements.

Partner with Product Development to evaluate manufacturability, identify process risks, and develop scalable manufacturing solutions while preserving the intended product design, functionality, and performance

Design, execute, and analyze laboratory, pilot, and commercial-scale trials to de-risk scale-up, establish process capability, and support commercialization decisions.

Establish process requirements, operating conditions, and technical success criteria to guide scale-up and commercialization decisions.

Commercialization and Technology Transfer Lead or support commercialization, process qualification, and technology transfer activities for new products and process changes.

Translate development knowledge into manufacturing requirements, process controls, operating windows, and specifications Assess manufacturing readiness, resolve technical gaps, and support startup and initial production activities.

Ensure effective transfer of technical knowledge, process risks, and operating guidance to manufacturing teams.

Develop or support qualification plans, acceptance criteria, technical protocols, and final reports that document process readiness, results, and residual risk.

Extrusion Technology Expertise Serve as a technical subject matter expert for extrusion technologies, particularly twin-screw extrusion.

Apply extrusion expertise to process development, scale-up, equipment evaluation, manufacturing support, and commercialization.

Develop and optimize process parameters, equipment configurations, control strategies, and operating windows.

Lead complex technical investigations involving extrusion equipment, raw materials, process performance, and product quality.

Contribute to capability development through standards, training, best practices, and evaluation of emerging technologies.

Manufacturing Support and Process Optimization Partner with Manufacturing to improve process safety, quality, reliability, efficiency, and capacity utilization.

Lead or support technical investigations and root-cause analysis, and partner with Manufacturing and other accountable functions to define and implement corrective actions and process improvements Analyze process data to identify variation, process limitations, and improvement opportunities.

Support lifecycle activities including process optimization, raw material…