Process Engineer
High Pressure Batch Reactors

Polysciences | Warrington, Pennsylvania | Onsite

Do you have hands-on experience with high-pressure chemical reactors and want to build deeper expertise? Polysciences is seeking a Process Engineer who enjoys working directly with equipment, solving practical problems, and learning alongside experienced technical partners.

Our specialty chemical manufacturing environment uses batch processing. You will develop batch processes in both our 2-gallon and 20-gallon high pressure reactors, while collaborating cross-functionally internally and with an external consulting firm.  You will work closely with the team to improve process efficiency through onboarding equipment upgrades, completing DOEs, and demonstrating batch-to-batch process capability.

We are looking for a foundation of relevant reactor experience, sound engineering knowledge and judgment, and a willingness to learn. You do not need to arrive as a high-pressure processing expert. You do need to be ready to work with the team and equipment, ask questions and steadily develop into an internal subject matter expert.

Scope of Role (What the work looks like)

Expect to regularly spend time in both research and production areas working with manufacturing technicians, R&D scientists and engineers to complete, observe and improve batch reactions. Work scope includes designing reaction processes, observing and monitoring reactions, fine tuning and troubleshooting process conditions and equipment, and continuous improvement of process, equipment and product for new product implementations. This role combines engineering design of equipment and process, data analysis for statistical process control, documentation to ensure a robust and repeatable process and direct hands-on work with the high-pressure equipment.

In this role you will get to gather information directly and indirectly, coordinate efforts cross-functionally, and identify and solve problems to design, develop, troubleshoot, improve and launch processes, systems and equipment for new product introductions. Experience at a large, small or medium-sized company can translate well if you are comfortable with this practical, resourceful and hands-on way of working to meet the day-to-day demands of batch manufacturing. Salary and title are based on experience and education.

Responsibilities (What you will do)

• Provide hands-on engineering support for high-pressure batch reactors, associated equipment, and process troubleshooting.
• Work with a cross-functional team, including but not limited to, engineers, R&D scientists, process technicians, quality and experienced consultants to understand and control process behavior and improve process robustness and equipment performance.
• Design and complete process trials and collect data; evaluate, select, install and qualify equipment; scale-up, validate and transfer processes to commercial production team; and ensure processes for production, equipment and cleaning are well defined and robust.
• Complete experiments and DOEs, analyze data and evaluate reaction parameters (pressure, temperature, time, materials, etc.) to establish robust processes that consistently adhere to high product quality standards.
• Build a thorough understanding of the reactor systems and processes to become an experienced, dependable high-pressure reaction SME. Leverage this knowledge to support other manufacturing areas as needed.
• Identify, recommend and coordinate the procurement, installation and qualification of engineering equipment, capital project improvements with a cross-functional internal team and with external suppliers, manufacturers, experts, etc.
• Develop and update process and cleaning instructions, SOPs, equipment specifications, PFDs, P&IDs, and technical reports; support technician training as your expertise develops.
• Participate in process safety reviews, risk assessments, root cause investigations, change control, equipment qualification and validation activities within our ISO 13485 quality system.

Requirements (What you will bring)

• A bachelor’s degree in Chemical Engineering.
• Direct, hands-on experience with high-pressure chemical reactors, including smaller batch, pilot, or specialty chemical systems.
• A thorough understanding of past equipment systems to be able to communicate equipment set up, operation, and the associated safety considerations and controls needed for operation.
• Experience in designing, overseeing and carrying out reactor operations, process trials, process and product development and data analysis for statistical process control.
• Experience in equipment design, procurement, installation and qualification.
• A minimum of 3-5 years of industry experience in chemical engineering for practical application understanding of heat transfer, reaction kinetics and thermodynamics, batch scaling and critical parameters (mixing rates, pressurization, rate of reaction, etc.).
• Willingness to work directly in a manufacturing environment, leaning new equipment and systems through training, research and supervised experience; seeking guidance when needed.
• A methodical approach to problem solving, clear communication, concise, complete and accurate documentation, and the ability to work with a cross-functional team. 

Related Experience (Helpful experience)

• Batch chemical manufacturing.
• Equipment and process scale-up.
• Technology transfer of existing processes and to production teams.
• Capital Equipment projects including the creation, review or approvals of Design Specifications, PFDs and P&IDs, process risk assessments, change controls, and installation documentation (FATs, SATs, IOPQs).
• Experience in an ISO 13485, ISO 9001, GMP, or other structured manufacturing quality environment.

Why this opportunity

This is an opportunity to further develop specialized reactor knowledge while contributing directly to a growing manufacturing capability. You will learn from internal teams and external specialists, work closely with the team running the process, and see the results of your engineering work at the equipment. We value curiosity and initiative, paired with the judgment to recognize limits, raise concerns, and put safe operation first.

When applying, please highlight the reactor systems you have worked with, whether they were batch or continuous, and what you personally did at the equipment. We are especially interested in candidates who want to build their careers around practical reactor and process engineering.

Qualifications

Education Required: Bachelor's Degree                                                 Preferred: Bachelor's Degree                     

Certification(s):Specify preferred or required.

Computer Skills Required:Specify preferred or required.

Proficiency with Microsoft Word and Excel required.

Experience with statistical software such as Minitab, JMP or Stat-Ease preferred.

Familiarity with SAP or similar ERP system and Blue Mountain or similar CMMS preferred.

Other qualifications:

• Bachelor’s degree in Engineering, chemical, industrial or mechanical preferred.
• Experience working in an ISO 13485 or FDA GMP environment preferred.  
• A minimum of 2 years of engineering experience in a manufacturing environment or similar required.
• Familiarity with process scale-up, optimization, cleaning and validation activities preferred.
• Knowledge of equipment specification, qualification and automation required.
• Expertise with procurement and maintaining production equipment preferred.
• LEAN / Six Sigma certification preferred.

Immediate Work Environment:

X-  Chemicals                     Unprotected Height            Fumes/Gases           Persistent Noise

X- PPE used: Lab Coat, Safety Shoes, Safety Glasses.

Work Activity: [must equal number of hours worked per day]              

Stand:     3             Frequency:  Intermittently                           Walk:     1             Frequency:  Intermittently          

Sit:          4             Frequency:  Intermittently                           Drive:      0             Frequency:  Choose an item.          

Lift/Carry Demands

Frequency:                                                            Lift/Carry Equipment Provided:

0-10 lbs.                 Less than 1 hour a day        Supporting equipment – tools, spare parts, etc.

11-25 lbs.              Not Daily                                Supporting equipment – hoses, lids, mixer props, etc.

26-50 lbs.              Not Daily                                Carts, Wheeled Reactors, Pallet Jacks of materials, etc.

51-75 lbs.              Never                                    

76-100 lbs.            Never