The Process Engineer is technically accountable for bridging Formulation and R&D Process Development to ensure products are scalable, robust, and factory ready. Operating within the Home Care R&D Process & Product Development teams, the role owns the translation of approved formulation intent into validated manufacturing processes through scale up, pilot trials, process specification, validation, and factory transfer.
The Process Engineer delivers assigned innovation and Value Improvement Project (VIP) workstreams, quality interventions, and capacity uplift through data driven, safe, and compliant execution, acting as the R&D technical authority for process development and scale up.
KEY RESPONSIBILITIES
R&D PROCESS DEVELOPMENT
Perform scale up studies to translate approved bench scale formulations into pilot and factory ready processes, defining process parameters, critical control points (CCPs) and critical quality attributes (CQAs).
Plan and perform experimental production runs in pilot plants and feasibility factory trials; provide technical recommendations and go / no go input based on agreed key success criteria. Prepare trial reports.
Create, validate, and issue process specifications and validation documentation, ensuring alignment with approved formulation specifications and maintaining audit ready version control.
Diagnose and resolve process deviations using engineering principles including root cause analysis and corrective actions.
Ensure compliance with GMP, PHAROS, QMS, and R&D safety standards across all trial activities, ensuring data integrity and first time right reporting.
Provide CAPEX technical input and requirements for new or modified process equipment, partnering with Engineering through trials, commissioning, and qualification.
Factory & Supply Chain Interface
Support technical problem solving for manufacturing issues in local HC factories, from issue diagnosis through validated resolution and standardisation.
Support in defining and optimising process parameters and operating windows for critical operations in collaboration with factory to improve stability, quality, and capability.
Maintain process operating instructions and SOPs; ensure accurate updates in manufacturing systems (e.g. RS Batch, FOXBORO, SCADA, DFOS, SPC) in line with change control requirements.
Co lead process audits; conduct, analyse, and report on factory process audits and formulation related process risks, ensuring timely technical closure of findings.
Act as R&D technical support in HAZOPs, dHACCPs, TRA, MOC, and TPM activities relevant to processes.
Support installation, commissioning, and qualification of powder related equipment as the R&D technical representative, ensuring required process capability is achieved.
Required Skills & Knowledge
Advanced / Expert
Process scale up from lab/bench scale into pilot and into factory manufacturing processes.
Collaborate with cross-functional teams and keep stakeholders informed. Communicate about new product commercialization and oversee factory processes to ensure consistent product quality.
Ability to interpret process data, define process windows, and validate scale up models.
Working Knowledge
Factory digital and control systems (SCADA, SAP, FOXBORO, PAMCO, DFOS, SPC or equivalents).
R&D and pilot plant testing methodologies and data interpretation.
QUALIFICATIONS & EXPERIENCE
BTech / BSc in Chemical Engineering (or equivalent)
3-5 years Demonstrated experience with independent technical ownership of process development and/or scaleup activities, or FMCG manufacturing