Process Engineering Lead

POSITION SUMMARY:

Reporting to the VP of Engineering, the Process Engineering Lead is responsible for leading process design, commercialization, and continuous improvement initiatives across bakery manufacturing operations. Leveraging deep expertise in dough systems, thermal processing, and high-speed production, this role ensures the successful scale-up of new products while optimizing efficiency, yield, and quality. The Process Engineering Lead partners closely with cross-functional teams to translate product innovation into reliable, high-performing manufacturing processes and leads capital projects from concept through startup to support business growth.

ESSENTIAL FUNCTIONS:

Bakery Process Design and Commercialization

• Leads the transition of bakery products from pilot to full-scale production, encompassing mixing, proofing, forming, baking, cooling, slicing, and packaging operations.
• Collaborates cross-functionally with R&D and Quality to ensure formulations are optimized for manufacturability, consistency, and food safety.
• Establishes, validates, and documents critical process parameters, including mix times, hydration levels, fermentation profiles, oven curves, and moisture targets.
• Drives and supports plant trials and the successful launch of new products and line extensions, ensuring seamless transition to production.

Capital Projects and Equipment Implementation

• Leads process design for bakery capital projects, including PFDs, P&IDs, line layouts, equipment specifications, and cost estimates.
• Specifies and implements bakery equipment such as mixers, dividers, proofers, tunnel ovens, conveyors, cooling systems, and packaging lines.
• Oversees installation, commissioning, validation, and startup of new production lines and system upgrades.
• Collaborates with contractors and vendors to deliver projects safely, on time, and within budget.

Continuous Improvement and Operational Excellence

• Drives improvements in yield, scrap reduction, downtime, and overall throughput.
• Leads root cause analysis for bakery-specific issues, including crumb structure, moisture variation, bake profile inconsistencies, and equipment reliability.
• Applies statistical tools, such as DOE and SPC, to improve process capability and consistency.
• Champions Lean and Six Sigma initiatives across production lines.

Utilities and Thermal Systems

• Provides engineering support for bakery utilities, including steam systems, ammonia refrigeration, compressed air, chilled water, and electrical infrastructure.
• Supports optimization of thermal systems, including oven performance, heat transfer efficiency, and energy utilization.
• Contributes to the development and improvement of preventive maintenance practices and process control systems, including PLC-based automation.
• Performs other duties and special projects as assigned by the VP of Engineering.

COMPETENCIES: 

To succeed in this role, the Process Engineering Lead must be self-motivated, detail-oriented, and able to manage multiple priorities effectively. The following knowledge, skills, and abilities are required:

• Strong business acumen, with the ability to connect process improvements to cost, yield, and product quality outcomes.
• Proven ability to optimize processes, improve yield, and ensure product quality and consistency.
• Experience launching new products and translating formulations into scalable production.
• Knowledge of capital project execution, including process design, equipment selection, and line startups.
• Strong problem-solving skills, including root cause analysis and data-driven process improvement.
• Ability to influence plant leadership and drive sustainable operational change.

EDUCATION AND EXPERIENCE: 

• Bachelor’s degree in Chemical, Mechanical, Food, or related Engineering field.
• Five (5)+ years of progressive experience in commercial bakery or thermal food manufacturing.
• Lean / Six Sigma certification
• Strong knowledge of dough rheology, fermentation, baking science, and moisture control.
• Experience with high-speed automated production lines and packaging systems.
• Proven experience leading capital projects collaborating cross-functionally.
• Solid understanding of GMPs, HACCP, sanitary design, and food safety standards.
• Experience with PLC systems (Allen Bradley preferred) and manufacturing automation.

TRAVEL: 

This position is based in La Vergne, TN. Domestic travel is required to support projects and initiatives, with an expected travel commitment of approximately 30%, depending on business needs.