Senior Process Engineer

Senior Process Engineer – Liquid Blending, Solids Blending, & Substrate Converting

Location: Harrodsburg, Kentucky

About the Role

A growing manufacturing company is seeking a Senior Process Engineer to lead and optimize key production operations including liquid blending, solids blending, and substrate converting. This role is ideal for a hands-on, results-driven engineer who thrives in a fast-paced, collaborative environment where innovation meets execution.

You’ll be instrumental in bridging the gap between R&D and full-scale production, ensuring that new product formulations are seamlessly scaled up with efficiency, quality, and cost-effectiveness in mind. This is a unique opportunity to play a key role in launching and expanding a state-of-the-art manufacturing facility.

Key Responsibilities

Process Design & Optimization: Develop, refine, and scale blending and converting processes to enhance output, minimize waste, and reduce downtime.

Product Scale-Up: Collaborate with R&D to transition new product formulas from pilot to commercial-scale production.

Plant Operations Support: Lead root cause analyses and implement continuous improvement strategies across the production floor.

New Facility Launch: Assist with equipment selection, layout design, commissioning, and ramp-up of new production lines.

Data-Driven Improvements: Use tools like Pareto charts, CPK analysis, and value stream mapping to identify and solve inefficiencies.

Quality & Compliance: Ensure that processes meet all safety, environmental, and regulatory standards; maintain SOPs and batch documentation.

Team Development: Train and mentor production operators and junior engineers to promote technical knowledge and operational excellence.

Safety Focus: Champion a culture of safety and sustainability across all aspects of the plant’s operation.

Qualifications

Required:

Bachelor’s degree in Chemical, Mechanical, Industrial Engineering, or related field

5+ years of hands-on experience in process engineering within liquid blending, solids blending, and substrate converting

Demonstrated success in scaling production from lab to full-scale operations

Experience supporting facility startups and commissioning new equipment

Strong problem-solving skills and experience in process troubleshooting

Proficiency with tools such as CPK analysis, fishbone diagrams, and value stream mapping

Familiarity with Lean Manufacturing, Six Sigma, or other continuous improvement frameworks

Willingness to travel up to 20% initially, 10% ongoing

Preferred:

Master’s degree in a related field

Lean Six Sigma Certification (Green or Black Belt)

Experience in consumer goods, personal/home care, or chemical manufacturing

Knowledge of automation and process control systems

Ready to make an impact?