Sr. Scale Up Process Engineer

About the Role:

The Senior Scale‑Up Process Engineer in the North America R&D Process Development team at Haleon plays a critical role in delivering innovation‑led growth across Haleon's Wellness and OTC portfolios. The position is responsible for developing manufacturing processes, defining control strategies, and leading the technical transfer of new products from prototype through commercialization.

• Develop and execute robust manufacturing processes and control strategies for new product introductions, ensuring products consistently meet quality requirements and consumer expectations.
• Lead scale‑up and technology transfer activities from laboratory and pilot‑scale development through commercial manufacturing, partnering closely with Supply Chain, Quality, Manufacturing, and R&D teams.
• Manage multiple projects of varying complexity, ensuring delivery of technical milestones while balancing timelines, risks, and business priorities.
• Design, execute, and analyze process development studies using scientific and statistical approaches, including Design of Experiments (DOE), to build process understanding and optimize manufacturing performance.
• Develop technical risk assessments, development reports, process characterization documentation, and technology transfer packages to support successful commercialization.
• Evaluate emerging process technologies and manufacturing approaches, identifying opportunities to improve efficiency, quality, and scalability.
• Build deep technical understanding of processing equipment across laboratory, pilot, and commercial scales to enable successful scale‑up and process transfer.
• Create, review, and approve GMP‑critical documentation, including batch records, experimental reports, development reports, and technology transfer documentation in compliance with quality and regulatory requirements.
• Demonstrate subject matter expertise in process development and scale‑up while effectively influencing stakeholders and driving cross‑functional alignment across project teams.

• Bachelor’s Degree in Engineering (Chemical or Biomedical preferred), Chemistry, Biology, Pharmaceutical Sciences, or a related scientific discipline.
• 10+ years of experience in process development within the pharmaceutical, chemical, food, consumer health, or related industries.
• 5+ years of experience supporting Consumer Health and/or FMCG product development processes.
• 5+ years of experience working within cGMP‑regulated environments.
• Strong analytical and problem‑solving skills with the ability to apply scientific rigor to complex technical challenges.
• Demonstrated leadership, communication, and influencing skills with the ability to effectively collaborate across matrixed organizations.
• Ability to successfully manage multiple complex projects in a fast‑paced, highly matrixed environment while delivering high‑quality results.
• Demonstrated commitment to continuous learning, knowledge sharing, and building strong collaborative relationships across functions.
• Experience leading scale‑up activities from laboratory or pilot plant environments through commercial manufacturing.
• Demonstrated track record in the development, scale‑up, and technical transfer of products, preferably including solid, liquid, and semi‑solid dosage forms.

• Master’s Degree or Doctor of Philosophy (PhD) in Engineering (Chemical or Biomedical preferred), Chemistry, Biology, Pharmaceutical Sciences, or a related field.
• Strong understanding of Quality by Design (QbD), process characterization, process understanding, and control strategy development.
• Experience developing and executing process development studies using Design of Experiments (DOE) and other engineering tools.
• Experience with Operational Excellence methodologies such as Lean, Six Sigma, Agile, or similar continuous improvement frameworks.

This role is hybrid and may be based in Warren, New Jersey or Richmond, Virginia.

Haleon offers a competitive pay package and a comprehensive benefits program that includes a generous 401(k) plan, tuition reimbursement, paid parental leave, health and dental coverage, and discretionary bonuses based on business performance.

Equal Opportunities:
Haleon is committed to building an inclusive culture where all employees feel they truly belong. We ensure fair treatment and compliance with all applicable employment laws.