Sr. Process Engineer

At Windfall Bio, we are pioneers in biotech innovation, tackling some of the world’s most critical environmental challenges. Our breakthrough solutions focus on capturing and transforming climate-harming methane emissions into beneficial products. Utilizing cutting-edge technology and methane-eating microbes, we convert methane from various sources into valuable outputs, such as organic fertilizers. This nature-based approach provides a sustainable method for industries like agriculture, oil and gas, and waste management to significantly reduce their carbon footprint and environmental impact. Join us in our mission to create a cleaner, greener future.

Role Overview

We are seeking a Senior Process Engineer with deep expertise in fermentation scale-up to join our demo plant operations in Houston, Texas. The ideal candidate will have hands-on experience designing, optimizing, and transferring fermentation processes from demo scale (100L–300L) through commercial manufacturing (5K- 30K liters). liters). This role requires a strong technical foundation in bioreactor operations, downstream processing, and process scale-up methodologies, with an emphasis on translating demo plant learnings into reliable, commercial-scale processes.

The Senior Process Engineer will act as a technical leader, driving process development, mentoring junior engineers, and ensuring smooth scale-up and tech transfer into full-scale production.

Key Responsibilities

• Fermentation Scale-Up & Tech Transfer
• Develop and implement scalable bioreactor operating and control strategies (batch, fed-batch, continuous).
• Design and execute scale-up strategies applying principles such as OTR, KLa, impeller design, and mixing dynamics.
• Translate demo plant data into robust commercial manufacturing processes, leading technology transfer efforts.
• Demo Plant Operations
• Lead daily operations of fermentation and downstream unit operations in the Houston demo facility.
• Support commissioning, qualification, and start-up of new demo-scale and commercial equipment.
• Provide hands-on troubleshooting and process optimization support in real time.
• Process Development & Optimization
• Design and analyze experiments using DoE/statistical methods to drive yield, consistency, and product quality improvements.
• Lead downstream process optimization including centrifugation, filtration (TFF), freeze drying, and spray drying.
• Develop SOPs, batch records, and operational narratives to support R&D, Quality, and Manufacturing teams.
• Leadership & Collaboration
• Mentor junior engineers and scientists, fostering a culture of technical excellence.
• Collaborate with cross-functional teams (R&D, QA/QC, Manufacturing, Regulatory) to ensure smooth process integration.
• Communicate technical findings and project updates effectively with internal teams and external partners/customers.
  
  

Qualifications

Education & Training:

• B.S. or M.S. in Chemical Engineering, Biochemical Engineering, Biotechnology, or related discipline.
• Ph.D. preferred but not required.
  
  

Experience:

• Minimum 7–10 years of relevant industrial bioprocessing experience, with at least 5 years focused on fermentation scale-up.
• Proven track record of scaling processes from lab and demo to commercial manufacturing.
  
  

Technical Skills:

• Expertise in fermentation kinetics, bioreactor design, and scale-up modeling.
• Proficiency in downstream separation and purification techniques.
• Strong statistical and data analysis skills using JMP, Minitab, or equivalent software.
  
  

Soft Skills:

• Strong leadership, mentorship, and project management abilities.
• Excellent problem-solving, troubleshooting, and communication skills.
• Ability to manage multiple priorities in a dynamic demo plant environment.
  
  

Work Environment & Physical Requirements

• Work primarily conducted in a demonstration plant setting with exposure to lab, process, and manufacturing equipment.
• Must be able to lift up to 30 lbs, stand for extended periods, and operate demo-scale equipment.
• Willingness to work hands-on with fermentation systems, downstream unit operations, and related process utilities.
  
  

The base salary range for this full-time position is $150 -$200k plus equity and benefits. The range displayed on each job posting reflects the minimum and maximum target for new hire salaries for the position across all locations. Within the range, individual pay is determined by factors including job-related skills, experience, relevant education or training, and location.

Windfall Bio prohibits unlawful discrimination based on race, color, religion, gender, sexual orientation, gender identity or expression, national origin or ancestry, age, disability, marital status and veteran status.