Senior Process Development Engineer

Human Resources Professional, Recently Award Delaware Valley HR Person of the Year 2025

About Air Joule, LLC

Are you passionate about making a difference in the fight against climate change? Then Air Joule is the place for you! We are a joint venture between GE Vernova and Montana Technologies, and a leader in the global sustainability transition. Our revolutionary atmosphere water harvesting technology enable transformative HVAC products that help our customers save money on their energy bills while reducing their environmental impact.

The same core technology also enables atmospheric water harvesting products that create clean, abundant, and decentralized water for industrial, commercial, and humanitarian purposes.

Position Summary

The Senior Process Development Engineer will define and lead our slurry and coating efforts and will play a critical role implementing and improving our coating technology. The role will design, improve, and operate our pilot scale slurry and coating processes, perform design of experiments (DOE) for coating and thermal curing process steps to optimize quality and productivity. The role will also work closely with the R&D team on new formulations and will be a key leader in the scale up of the pilot process to full production.

The role will also play an integral part of our scale‑up efforts, taking our pilot scale process to full scale manufacturing.

Key Responsibilities

To perform in this position successfully, an individual must be able to perform each key responsibility satisfactorily. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. Other duties may be assigned to meet business needs.

• Lead new equipment specification and procurement for slurry process, coating lines, and oven curing manufacturing processes.
• Lead pilot plant design engineering, including electrical requirements, emissions handling, waste handling, and other utility and process needs.
• Lead process optimization research, including all parts of our coating process.
• Lead the pilot plant operations team in a safe and efficient manner while attending to technical details during the operation.
• Safely handle chemicals used in current and future formulations.
• Safely manage waste profiles and quantities in compliance with applicable regulations.
• Manage scale up operations experiments and data through an electronic lab notebook.
• Support change management by training teams on new processes and best practices.
• Collaborate with engineering, operations, quality, and leadership teams to align improvements with business goals.
• Analyze existing processes to identify inefficiencies, bottlenecks, and root causes of performance gaps.
• Lead continuous improvement initiatives using Lean, Six Sigma, Kaizen, and DMAIC methodologies.
• Develop and implement process improvements that enhance productivity, quality, safety, and cost performance.

Education and Experience Requirements

• Minimum Education: Bachelor's degree in Chemical Engineering
• Minimum Experience: 10 years of proven chemical engineering experience, preferably with direct experience designing and operating pilot coating or similar facilities.
• Preferred Certification: Green Belt Six Sigma

Knowledge,

Skills and Abilities

• General knowledge of safe laboratory and industrial practices.
• Detail‑oriented with excellent multitasking and collaboration skills.
• Proficiency with JMP.
• Experience with Design of Experiments (DOE).
• Scale up experience a plus.
• Strong familiarity with equipment sizing and specifications.
• Experience with powder handling and mixing.
• PSM Experience strongly preferred.
• Proficiency with Microsoft office.
• Strong organizational, analytical, detail‑oriented and problem‑solving skills.
• Excellent written and oral communication skills.

Other Requirements

• Applicants must be authorized to work for any employer in the U.S. Air Joule is unable to sponsor or take over sponsorship of an employment Visa at this time.

Mid‑Senior level

Full‑time

Engineering, Science, and Manufacturing

Climate Technology Product Manufacturing