Process Engineer

Senior Engineer - Process Engineering: Roles & Responsibilities

Process Engineering & Technical Documentation

• Develop, review, and update P&IDs (Piping & Instrumentation Diagrams) and PFDs (Process Flow Diagrams).
• Prepare mass and energy balances, equipment layouts, and plant drawings.
• Create equipment specifications for mixers, conveyors, dosing systems, and dust collection systems.
• Support process safety reviews and HAZOP studies. Scale-Up & New Product Commercialization
• Convert laboratory formulations into large-scale manufacturing processes.
• Lead scale-up and commercialization of powder and liquid products.
• Conduct DOE (Design of Experiments), process trials, and equipment validation.
• Execute IQ, OQ, and PQ validation activities.

Process Optimization & Continuous Improvement

• Improve cycle time, productivity, and manufacturing efficiency.
• Enhance batching accuracy and material handling systems.
• Optimize dust collection and conveying operations.
• Apply Lean Manufacturing and Six Sigma methodologies to drive operational excellence.

Packaging Development

• Collaborate with QA, R&D, Marketing, and Packaging teams to develop new packaging materials.
• Conduct drop tests, transportation tests, shower tests, and packaging validation trials.
• Qualify films and laminates for moisture protection and shelf-life requirements.

CAPEX & Project Management

• Manage greenfield and brownfield projects from concept through commissioning.
• Prepare project budgets and investment justifications.
• Coordinate vendor selection, FAT, SAT, installation, and start-up activities.
• Drive plant expansion and equipment upgrade projects.

Automation & Digitalization

• Implement automation solutions to improve productivity and process control.
• Eliminate non-value-added activities through automation initiatives.
• Improve manufacturing traceability, visibility, and operational efficiency.

Cross-Functional Collaboration

• Work closely with R&D, Production, Quality, Supply Chain, and Packaging teams.
• Manage external vendors and equipment suppliers.
• Ensure compliance with EHS, quality, and regulatory standards.

Key Responsibilities Summary

• Process Engineering
• Process Optimization
• Scale-Up & Commercialization
• P&ID / PFD Development
• DOE & Process Validation
• Lean Six Sigma
• CAPEX Management
• Automation Projects
• Packaging Development
• Material Conveying & Dust Collection
• Mixing Technology
• Continuous Improvement
• HAZOP & Process Safety
• Project Management
• Vendor Management
• Cross-Functional Collaboration

Role Snapshot: A hands-on Process Engineering professional responsible for manufacturing scale-up, process improvement, automation, CAPEX execution, packaging development, and operational excellence within construction chemicals or related process manufacturing industries.