Senior Process Engineer

Senior Process Engineer

Location: Holland, MI

Reports to: Director of Engineering

The Senior Process Engineer is responsible for the design, optimization, and continuous improvement of food production processes across manufacturing operations. This role ensures that processing systems are efficient, scalable, compliant with food safety regulations, and aligned with operational and capital objectives. The Process Design Engineer partners with Operations, Maintenance, Quality, R&D, and external vendors to support new product launches, capacity expansions, and process improvements.

• Design and develop food production processes, including mixing, cooking, baking, extrusion, forming, packaging, and material handling systems.
• Create and maintain Process Flow Diagrams (PFDs), P&IDs, and equipment specifications.
• Conduct line capacity analysis and throughput modeling to assess operational performance.
• Evaluate process capability and identify opportunities for yield, efficiency, and quality improvements.
• Lead pilot testing, scale‑up activities, and validation of new processes.
• Support capital project planning from conceptualization through commissioning.
• Develop detailed equipment specifications and actively participate in vendor selection.
• Review equipment layouts to ensure compliance with hygienic design standards.
• Oversee installation, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and startup of new production lines.
• Ensure timely and cost‑effective completion of projects.
• Analyze production data to pinpoint bottlenecks and process inefficiencies.
• Implement Lean, Six Sigma, or comparable methodologies to enhance performance.
• Drive initiatives to improve yield, minimize waste, and optimize ingredient utilization.
• Support Overall Equipment Effectiveness (OEE) improvement efforts.
• Conduct root cause analysis to address recurring process challenges.
• Ensure all process designs adhere to USDA and GMP requirements.
• Integrate hygienic design principles within equipment layout and selection.
• Collaborate with Quality and Food Safety teams on validation and verification protocols.
• Contribute to HACCP plan development and risk assessments for new processes.
• Maintain compliance with OSHA and environmental regulations.
• Partner with R&D throughout new product development and commercialization phases.
• Work closely with Maintenance to support equipment reliability and maintainability.
• Collaborate with Operations to resolve production challenges.
• Provide training for operators on new equipment and process implementations.
• Participate in sustainability initiatives focused on energy, water, and waste reduction.
• Develop comprehensive standard operating procedures (SOPs) for new processes.
• Maintain thorough engineering documentation and change management records.
• Ensure proper validation and recordkeeping for regulatory audits.
• Support the management of process control strategies and integration of automation.

Key

Qualifications:

• Bachelor’s degree in Mechanical Engineering, Industrial Engineering, or related field.
• 5–8+ years of process engineering experience in food manufacturing or a regulated CPG environment.
• Strong knowledge of food manufacturing and sanitary system design.
• Experience with AutoCAD, Solid Works, or similar design software.
• Familiarity with PLCs, process controls, and automation integration.
• Understanding of GMPs, HACCP, and food safety standards.
• Experience supporting capital projects.
• Strong analytical and problem‑solving skills.
• Excellent communication and cross‑functional collaboration abilities.

Preferred Qualifications:

• Experience with high‑speed packaging lines.
• Knowledge of hygienic design standards (3‑A, EHEDG).
• Experience in frozen, refrigerated, or shelf‑stable food manufacturing environments.