Senior Plant Engineer

Senior Plant Engineer

Guardian Energy Janesville has an exciting opportunity for a Senior Plant Engineer to join the team. This role provides technical and operational leadership for capital projects, process optimization, plant reliability, safety, and continuous improvement. The Senior Plant Engineer reports to the Plant Manager and works with plant leadership to improve profitability, strengthen operating discipline, and ensure safe, consistent, and compliant plant performance.

Essential Functions and Basic Duties

• Lead the identification, evaluation, prioritization, and execution of capital and continuous improvement projects that increase production, improve yield and efficiency, strengthen reliability, or reduce operating costs. Develop scope, business justification, budgets, schedules, risk assessments, implementation plans, and performance verification.

• Analyze plant operating data and Key Performance Indicators (KPIs), including production volume, yield, uptime, quality, energy use, utility consumption, and operating cost. Maintain effective monitoring and reporting tools that identify trends, risks, and improvement opportunities.

• Provide senior-level technical support for process troubleshooting, root-cause analysis, debottlenecking, process control, and sustained corrective action.

• Partner with the Plant Manager, Shift Leads, operators, maintenance, quality, and other functions to ensure safe and consistent operation across shifts in accordance with established standards and SOPs.

• Coordinate internal resources, vendors, and contractors for plant trials, process changes, equipment modifications, commissioning, startup, and performance testing.

• Lead the development, review, and continuous improvement of Standard Operating Procedures, operating limits, training materials, P&IDs, block flow diagrams, process narratives, and other engineering records.

• Provide technical coaching and guidance to Shift Leads, operators, and less-experienced engineers; help build plant problem-solving and process knowledge.

• Coordinate Process Safety Management implementation and execution with plant leadership, including Management of Change, Pre-Startup Safety Review, incident investigation, Process Hazard Analysis, chemical inventory, and labeling requirements.

• Support compliance with EPA Title V, OSHA, FSMA, and other applicable regulatory requirements; help ensure process areas remain within established operating and environmental parameters.

• Provide engineering leadership for planned shutdowns, including scope development, planning, scheduling, resource coordination, contractor support, execution, and startup readiness.

• Serve as a technical and operational resource during plant upsets, outages, and other high-priority events, and provide Shift Lead coverage when business needs require and the individual is qualified. Occasional work outside the normal schedule may be required.

• Participate in hiring, onboarding, training, performance feedback, work direction, and resolution of employee concerns in partnership with the Plant Manager.

• Lead special projects and perform other duties as assigned.

Qualifications

Education

• Bachelor's degree in Chemical Engineering, Process Engineering, or a closely related engineering discipline required.

Required Knowledge and Experience

• Five or more years of progressive engineering experience in ethanol, chemical, food, fuel, bio-processing, or another continuous-process manufacturing environment.

• Demonstrated experience leading capital or continuous improvement projects from concept and justification through startup and performance verification.

• Strong working knowledge of production processes, process controls, equipment systems, and plant operating practices.

• Demonstrated ability to analyze complex operating data, identify root causes, and convert findings into practical, sustainable improvements.

• Experience working with Distributed Control Systems (DCS) and collaborating with operators to improve process control and operating consistency.

• Working knowledge of Process Safety Management practices, including Management of Change, Pre-Startup Safety Review, incident investigation, and Process Hazard Analysis.

• Ability to lead cross-functional work, influence without relying solely on authority, and communicate effectively with employees at all organizational levels.

• Proficiency with Microsoft Office and data-analysis tools.

Preferred Qualifications

• Experience in the operation or engineering support of a dry-mill ethanol facility.

• Experience with process-modeling software such as Aspen Plus or ChemCAD.

• Familiarity with pressure vessels, relief systems, and applicable ASME and API standards.

• Experience supporting environmental, food-safety, or other regulated manufacturing requirements.

• Prior experience coaching technical employees or providing day-to-day leadership to production teams.

Skills and Abilities

• Exercises sound engineering judgment and can balance safety, quality, production, cost, and schedule considerations.

• Communicates technical information, operating risks, and recommendations clearly and concisely to both technical and nontechnical audiences.

• Builds effective working relationships and earns credibility with operators, maintenance employees, contractors, peers, and leadership.

• Organizes multiple priorities, follows projects through completion, and responds effectively to changing plant needs.

• Develops others by sharing knowledge, setting clear expectations, and providing constructive feedback.

Physical Requirements and Work Environment

This position requires the ability to work in an operating plant environment and occasionally lift up to 50 pounds. The role may require climbing stairs and ladders, entering production areas, wearing required personal protective equipment, and responding to plant needs outside normal business hours. Reasonable accommodations may be made to enable qualified individuals to perform the essential functions.

Compensation and Benefits

At the time of posting, the salary for this position ranges from $95,000 to $130,000. Compensation will be determined based on a variety of factors, including but not limited to relevant skills, experience, and qualifications.

Guardian Energy offers a comprehensive benefits package that includes:

• Competitive wages, paid holidays, bonus eligibility, and generous time off

• Low-cost medical, dental, and pharmacy plans

• Healthcare and dependent care flexible spending accounts

• Guardian HSA contributions

• Disability and employer-paid life insurance

• Excellent retirement plans with employer contribution

• Employee Assistance Program at no cost to employees

• Continuous learning opportunities supported by a tuition reimbursement program