Process Control Engineer

Process Engineer - Specialty Polymers Manufacturing

Location : Spartanburg, SC

Department: Manufacturing / Operations

Reports To : Operations Manager

Employment Type : Full-Time

Salary Range ($100K - $125K)

Join Our Team
We are seeking a highly motivated Process Engineer to support and optimize manufacturing operations within our specialty polymers production facility. This role is responsible for improving process efficiency, product quality, safety performance, and manufacturing reliability while supporting the production of high-performance polymer products used in diverse industrial and consumer applications.


The ideal candidate will have experience in polymer processing, chemical manufacturing, continuous improvement, and process troubleshooting, with a passion for driving operational excellence in a fast-paced manufacturing environment.



Key Responsibilities
Process Optimization & Manufacturing Excellence

• Monitor and optimize polymerization, extrusion, pelletizing, and solid-state polymerization operations.
• Analyze production data to improve yield, throughput, process capability, and overall equipment effectiveness (OEE).
• Identify and implement process improvements that reduce waste, increase productivity, and enhance product consistency.
• Support process scale-up activities from pilot production to full commercial manufacturing.
• Develop process models, mass balances, and production performance metrics.

Production Support & Troubleshooting

• Provide daily technical support to manufacturing operations.
• Investigate process deviations, off-specification material, equipment issues, and customer quality concerns.
• Lead root cause analysis and corrective action initiatives using structured problem-solving methodologies.
• Support production startups, shutdowns, grade changes, and new product introductions.
• Work closely with operators and supervisors to maintain stable and efficient operations.

Quality & Product Performance

• Partner with Quality and Technical Service teams to ensure products meet customer specifications.
• Evaluate critical polymer properties including viscosity, molecular weight, melting point, density, particle size, and mechanical performance characteristics.
• Support product qualification efforts and process validation activities.
• Drive initiatives that improve product consistency and reduce quality defects.

Safety & Regulatory Compliance

• Maintain compliance with all company safety standards and regulatory requirements.
• Participate in Process Hazard Analyses (PHA), HAZOP studies, Management of Change (MOC), and Process Safety Management (PSM) programs.
• Identify and mitigate process safety risks associated with chemical reactions, raw materials, and polymer processing equipment.
• Promote a strong safety culture throughout the facility.

Capital Projects & Engineering Support

• Support capital improvement and equipment installation projects.
• Develop process flow diagrams (PFDs), P&IDs, equipment specifications, and operating procedures.
• Collaborate with maintenance, engineering, contractors, and equipment vendors.
• Participate in commissioning and startup activities for new equipment and process modifications.

Continuous Improvement

• Lead Lean Manufacturing and Six Sigma initiatives.
• Identify cost-saving opportunities related to raw materials, utilities, production efficiency, and waste reduction.
• Enhance process reliability and reduce manufacturing downtime.
• Support sustainability initiatives focused on energy efficiency, recycling, and emissions reduction.

Required Qualifications

• Bachelor's degree in Chemical Engineering, Polymer Engineering, Materials Engineering, or related technical field.
• 3+ years of manufacturing experience in polymers, specialty chemicals, plastics, resins, compounding, or related industries.
• Strong understanding of chemical process operations and polymer manufacturing processes.
• Experience analyzing manufacturing data and implementing process improvements.
• Knowledge of process safety principles and industrial safety practices.
• Strong problem-solving and analytical skills.
• Effective communication and cross-functional collaboration skills.

Preferred Qualifications

• Experience with polymerization reactors, extrusion systems, compounding lines, or pelletizing operations.
• Knowledge of specialty polymers such as:
  • Engineering thermoplastics
  • Polyurethane systems
  • Functionalized polymers
  • Elastomers
  • Specialty resins and additives
  • Experience with Minitab, Aspen Plus, Aspen HYSYS, JMP, or similar analytical tools.
  • Six Sigma Green Belt or Black Belt certification.
  • Experience with SAP or manufacturing ERP systems.
  • Familiarity with Statistical Process Control (SPC).

Key Competencies

• Polymer processing knowledge
• Process optimization
• Manufacturing troubleshooting
• Root cause analysis
• Data analytics
• Process safety
• Continuous improvement
• Project management
• Technical leadership
• Collaboration and communication

Physical Requirements

• Ability to work in an industrial manufacturing environment.
• Frequent plant floor presence required.
• Ability to climb stairs, ladders, and access process equipment.
• Ability to wear required PPE.
• Occasional lifting up to 25 pounds.
• Availability for occasional off-shift support and emergency response activities.

What We Offer (Check/review)

• Competitive salary and annual bonus opportunity
• Comprehensive medical, dental, and vision coverage
• 401(k) with company match
• Career growth and professional development opportunities
• Exposure to innovative specialty polymer technologies
• Collaborative and safety-focused work environment

Apply Today
If you are passionate about manufacturing excellence, process innovation, and developing high-performance polymer products, we encourage you to apply and join our growing specialty polymers team. You will play a key role in shaping the future of advanced materials while driving safety, quality, and operational performance.

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