Process Engineer III

At Thorne, we work to deliver high-quality, science-backed solutions to empower individuals to take a proactive approach to their well-being. Each day begins with a mission to help others discover and achieve their best health. We count on our team members to challenge and push the boundaries to make that happen. At Thorne, you’ll be joining a team of more than 750 passionate individuals committed to our cause of providing superior health solutions at every age and life stage.

Position Summary:  The Process Engineer III is a Subject Matter Expert (SME) and ensures that all necessary components, tasks, and resources are capable of meeting established quality standards and goals and supports department operations to ensure compliance with cGMP and OSHA regulations, company Standard Operating Procedures (SOPs) as well as meeting production goals as directed.

This role provides full relocation assistance. 

Responsibilities

• Apply engineering and science fundamentals to create new methods and programs that lead to production and process improvements. 
• Extensive documentation of existing process flows using Visio and creating baselines for future improvements.
• Lead cross-functional teams to create detailed PFMEAs for all major Thorne manufacturing processes, compile mitigation plans for high-risk areas and execute corrective & preventative actions.
• Investigate chronic performance issues with Thorne’s manufacturing processes and/or SKUs, initiate and lead projects, form teams of process engineers & technicians to provide optimal solutions.
• Optimize and scale production processes and batch sizes to expand capacity without compromising quality, efficiency, or compliance. 
• Conduct process trials and lab experiments including benchwork formulation, powder characterization, encapsulation or as directed by the Engineering Manager and provide detailed analysis.
• Support Product Development by performing technical assessments for New or Clinical Trial products.
• Maintain lab equipment and all test procedures to ensure compliance with Quality & Regulatory requirements.
• Research new process equipment and with end user(s) create equipment User Requirement Specifications (URS).  
• Research and maintain knowledge of new processing technologies applicable to Thorne’s processes and provide executable recommendations to leadership.
• Identify any gaps in skill sets of Process Engineers & Technicians, provide developmental guidance & mentoring.
• Create a comprehensive process engineering knowledge base with systems for periodic reviews & updates in order to keep current with plant-wide continuous improvement efforts.

Production Support responsibilities include but are not limited to the following:

• Current powder blending & mixing process improvements and optimization.
• SOP / Change Control generation & technical review if necessary. 
• Identify gaps in processing equipment capabilities and recommend alternatives.
• Perform Powder Characterization testing to address problems discovered prior to encapsulation.
• As the SME, provide technical support and advice in response to processing problems to other groups as requested by the Engineering Manager.
• Occasional support of MRB activities including Root Cause Analysis (RCA) will be required.
• Occasional support of Process Validation activities will be required.
• Evaluate data and provide reports to management on a variety of topics as requested by the Engineering Manager.  
• Coordinate with vendors concerning raw material problems and their solutions as directed by leadership.
• Perform Corrective Action responses to various audit or production related problems as directed by leadership.

What You Need

• Bachelor’s degree in Mechanical Engineering, Chemical Engineering, Food Science/Engineering or similar scientific field, with documented combination of education and experience readily available
• 5 years’ hands-on experience in Process Development & Process Engineering in FDA-regulated Pharma/Nutra environment is required
• Alternatively, a candidate may have a Master’s degree in the applicable fields and 3 years of relevant experience and must demonstrate time management, project management, and leadership skills.  
• Powder characterization, mixing/blending and bulk material handling & processing experience is required.
• Experience working with lab equipment, pilot jobs and experimentation following GLP standards is preferred.
• Experience in encapsulation of HPMC capsules using tamping style high speed equipment is highly preferred.
• Possess knowledge of Statistics, Design of Experiments (DOE) and, highly skilled at Minitab, Visio and generating detailed project schedules using MS Project.
• Experience in using scientific and structured problem solving techniques is required.
• Comprehensive knowledge of creating detailed PFMEAs at a SME level is required.

What We Offer

• Competitive compensation
• 100% company-paid medical, dental, and vision insurance coverage for employees
• Company-paid short- and long-term disability insurance
• Company- paid life insurance
• 401k plan with employer matching contributions up to 4%
• Gym membership reimbursement
• Monthly allowance of Thorne supplements
• Paid time off, volunteer time off and holiday leave
• Training, professional development, and career growth opportunities

Thorne is the leader in science-backed health and wellness solutions committed to helping individuals live healthier longer. As the top recommended clinical brand by healthcare practitioners, Thorne offers a comprehensive range of products including nutritional supplements and health tests designed to meet the unique needs of individuals at every stage of life. Founded in 1984, Thorne products are formulated with the highest-quality ingredients, supported by clinical research, and rigorously tested to ensure purity, potency, and efficacy. Thorne is trusted by 47,000 health-care professionals, thousands of professional athletes, more than 100 professional sports teams, multiple U.S. National Teams, and more than five million consumers. For more information, visit Thorne.com.

THORNE IS AN EQUAL OPPORTUNITY EMPLOYER 

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