Extrusion Scientist - Decatur, IL

Extrusion Scientist - Decatur, IL

Position Summary
Extrusion Scientist II role is an independent technical contributor responsible for leading innovation in extrusion-based food systems, with a focus on plant-based proteins and ingredient functionality. This role owns projects from concept through commercialization, applying advanced food science and process engineering expertise to deliver scalable, high-quality solutions.

Key Responsibilities

• Independently design, execute, and lead pilot-scale extrusion trials and experiments
• Manage R&D projects from concept through commercialization, ensuring timelines and technical deliverables are met
• Apply advanced understanding of ingredient functionality, formulation, and extrusion processing
• Analyze complex datasets and translate results into actionable insights and recommendations
• Provide troubleshooting process and scale-up support for manufacturing operations
• Conduct detailed product characterization (texture, rheology, structure-function relationships)
• Ensure full compliance with food safety, quality, and regulatory standards
• Lead technical communication with cross-functional teams (R&D, Operations, Commercial)
• Apply statistical tools (DOE, regression analysis, multivariate analysis) to design experiments, optimize processes and ensure robust, data-driven decision making
• Mentor junior scientists and contribute to capability development
• Support capital projects and continuous improvement of pilot extrusion capabilities
• Champion safety culture and ensure adherence to lab and plant safety protocols

Qualifications

• Bachelor’s degree with 3–5 years of experience OR master’s degree in food science, Chemical Engineering, Food Engineering, or related field
• Proven experience with pilot or commercial extrusion systems (single and twin screw)
• Demonstrated expertise in protein texturization, plant-based systems, or complex food matrices
• Strong problem-solving, experimental design, and data analysis skills
• Ability to independently manage projects and influence cross-functional stakeholders

Core Competencies
Technical & Engineering

• Advanced extrusion processing, scale-up, and troubleshooting
• Experimental design, statistical analysis, and process optimization
• Strong understanding of thermomechanical processing and rheology
• Statistical analysis and experimental design (DOE, ANOVA, regression modeling)
• Ability to interpret complex multivariate datasets and process variability

Food Science (Critical Competency)

• Deep knowledge of ingredient functionality (proteins, starches, fibers, lipids)
• Structure–function relationships in extruded food systems (texture, water binding, stability)
• Food formulation design for plant-based and protein-rich products
• Impact of processing conditions on sensory, nutritional, and functional attributes
• Food safety expertise (HACCP, GMP, allergen control, hygienic design)

Professional Skills

• Project ownership and project execution excellence
• Cross-functional leadership and stakeholder influence
• Clear technical communication and documentation
• Mentorship and knowledge sharing