Job Information
Balchem Process Engineer -Liaison R&D and Operations in Faribault, Minnesota
Process Engineer -Liaison R&D and Operations
Department: Zumbro
Location: Faribault, MN
Start Your Application (https://apply.hrmdirect.com/resumedirect/ApplyOnline/Apply.aspx?req_id=3656485&source=3656485-CJB-0)
COMPANY OVERVIEW:
Balchem Corporation develops, manufactures, and markets specialty ingredients that improve and enhance the health and well-being of life on the planet, providing state-of-the-art solutions and the finest quality products for a range of industries worldwide. Our corporate headquarters is located in Montvale, New Jersey and we have a broad network of sales offices, manufacturing sites, and R&D centers, primarily located in the US and Europe. Founded in 1967, Balchem is a publicly traded company (NASDAQ - -BCPC-) with annual revenues over $900 million and a market cap exceeding $4.0 billion. The company consists of three business segments: Human Nutrition & Health; Animal Nutrition & Health; and Specialty Products. Balchem employs over 1,400 people worldwide who are engaged in diverse activities, committed to developing the company into global market leadership positions. To learn more about our dynamic, stable and growing company, visit www.balchem.com.
POSITION SUMMARY:
The Process Engineer is responsible for optimizing and sustaining manufacturing processes to ensure safety, quality, compliance, and efficiency across the facility. This role serves as the primary liaison between R&D and Operations, translating new formulations and product designs into scalable, compliant, and cost-effective production processes. The position leads plant trials, manages technology transfer, and drives continuous improvement aligned to OEE, yield, and cost targets while upholding HACCP, GMP, allergen control, sanitation, and regulatory requirements (e.g., FDA/USDA, FSMA). This role is cross functional and interfaces with many different departments including R&D, Project Engineers, Manufacturing Personnel and others to help drive projects to successful completion.
ESSENTIAL FUNCTIONS:
Manufacturing Process Engineering
Develop, optimize, and standardize processes to improve throughput, yield, and OEE, reducing waste (giveaway, rework, hold/release).
Lead structured root cause analysis (5 Whys, Fishbone, DMAIC) and implement CAPAs for process deviations, micro fails, or quality events.
Conduct time studies, line balancing, and process mapping to remove bottlenecks and minimize changeover, clean-in-place (CIP) time, and downtime.
Establish and maintain process parameters (e.g., temperatures, dwell times, viscosities, moisture/aw, pH) and corresponding control limits.
Create and update SOPs, batch sheets, job aids, control plans, PFMEAs, and one-point lessons for the production floor.
R&D / Operations Liaison
Serve as the bridge between R&D, Plant Ops, and Supply Chain to ensure seamless NPI (new product introduction), reformulations, and material changes.
Translate lab/pilot recipes into manufacturable processes-including scale-up parameters, equipment capability, and control strategies.
Plan and execute pilot runs, line trials, FPRs (first production runs)-ensuring material readiness, line setup, sampling plans, and operator training.
Provide manufacturability and cost-in-use feedback early in development (ingredient sourcing, allergen segregation, sanitation impact, shelf-life).
Capture learnings, yields, and performance data during trials and communicate back to R&D for formulation or spec adjustments.
Equipment, Technology & Data
Assess equipment capability; specify, commission, and validate mixing, thermal processing (HTST, UHT, retort, baking/frying), forming, filling/packaging, and cooling systems.
Lead process validation and capability studies (Cp/Cpk), MSA, and SPC monitoring for critical parameters (e.g., fill weight, seal integrity, temperature).
Use data analytics to monitor process drift and drive decisions; partner with Maintenance on reliability improvements (PMs, CBM, MTBF/MTTR).
Continuous Improvement & Cost
Lead and support operational excellence initiatives (SMED, Kaizen, 5S, visual management) to reduce losses (scrap, micro/quality failures, overfill/giveaway, utilities).
Identify and implement automation/digitalization (e.g., inline vision, mass flow meters, PID control improvements, recipe management, MES/SCADA enhancements).
Build robust CIPs with financial impact-track benefits to plan (yield %, OEE %, $/lb or $/case, energy/water intensity).
Training & Cross-Functional Collaboration
Train operators and supervisors on new processes, CCP monitoring, sanitation impacts, and critical-to-quality attributes.
Work closely with Quality, Sanitation, Maintenance, Supply Planning/Procurement, EHS, and R&D to hit service, quality, and cost targets.
REQUIREMENTS:
Bachelor-s degree in Chemical, Mechanical, Industrial, Food, or Manufacturing Engineering (or related).
5+ years in manufacturing environment (process engineering, production support, or scale-up).
Working knowledge of HACCP/FSMA, GMPs, CCPs, allergen control, sanitation/CIP, and basic microbiology/shelf-life concepts.
Demonstrated experience with SPC, root cause analysis, and CI methodologies.
Strong communication skills to translate technical concepts across R&D, QA, and Operations.
WORKING CONDITIONS
Frequent exposure to manufacturing environment.
Exposures to dust, noise, and chemicals requiring wearing Personal Protective Equipment.
Physical requirements: Ability to stand, walk, climb stairs in manufacturing environment.
Travel of up to 50% of time will be required. Travel will be both domestic and international.
#IN
Balchem is committed to a workplace culture that values and promotes diversity, inclusion, equal employment opportunities, and a work environment free of harassment and hostility.
Start Your Application (https://apply.hrmdirect.com/resumedirect/ApplyOnline/Apply.aspx?req_id=3656485&source=3656485-CJB-0)