Senior Process Engineer

BIOFerm, a Wisconsin-based renewable energy company, is currently looking for a Senior Process Engineer. We specialize in turnkey anaerobic digestion and biogas upgrading facilities. Our mission is to provide sustainable, economical solutions for organic waste diversion by transforming food waste, manure, biosolids, and other organic materials into renewable natural gas (RNG), green energy, vehicle fuel, heat, and organic products.

The Senior Process Engineer leads the process design of BIOFerm's anaerobic digestion and biogas upgrading facilities from concept and permitting through construction, commissioning, and start-up. This role sets engineering scope and schedules, reviews other engineers' work, and partners with Project Management, Business Development, Construction, and Commissioning. The ideal candidate will combine deep process expertise with hands‑on project experience and strong technical leadership, including mentoring other engineers.

This is a full-time, on‑site role based in Madison, WI.

• Own the process design package for assigned projects — project specifications, conceptual design, PFDs, mass and energy balances, equipment sizing calculations, P&IDs, and operation manuals — and ensure it meets client requirements, applicable codes, and company design standards.
• Drive optimization of equipment and facility performance, including root‑cause analysis of underperforming assets and development of corrective design changes.
• Prepare and approve design outputs, datasheets, and drawings, and serve as technical reviewer of design work produced by other engineers.
• Lead the permitting process, including agency interface and preparation of technical submittals.
• Establish and manage vendor relationships, develop technical specifications, evaluate bids, and lead technical negotiations with suppliers.
• Submit purchasing requests with equipment specs in company’s system.
• Serve as the lead process engineering contact to the Project Team and other department engineers, setting engineering scope, sequence, and deliverable schedules to facilitate smooth progress of engineering work.
• Review and approve the final plant/process design.
• Advise the Project Manager on design modifications during construction, including technical, cost, and schedule impact.
• Support the Construction Team during construction phase and carry out site checks.
• Support the Commissioning Team during plant start‑up.
• Conduct tests and monitor the process performance.
• Lead troubleshooting and resolution of complex process problems escalated from projects and operating plants.
• Evaluate processes and equipment to ensure compliance with environmental, safety, and quality standards.
• Assemble reports and document processes.
• Support the operation engineering team.
• Lead cross‑functional teams.
• Evaluate and recommend new processes, technologies, and equipment, and lead their introduction into the standard design.
• Partner with Business Development on project development, technical proposals, schedules, and budgets.
• Perform and validate process design and simulations for major plant components.
• Mentor and provide technical guidance to less experienced engineers, including review and checking of their calculations, datasheets, and drawings.
• Develop and maintain process design standards, calculation templates, and engineering best practices, and drive their adoption across projects.
• Lead process safety reviews (PHA/HAZOP) and ensure resulting action items are closed in the design.
• Serve as a technical authority in client‑facing meetings and design reviews.
• Perform other tasks and special projects as may be assigned.

• Bachelor's degree in Chemical or Mechanical Engineering required; master's…