Description:
At Epsilyte LLC, we are seeking a highly motivated and results-driven Senior Process Engineer to support our EPS manufacturing operations in a PSM-covered environment. This role will be responsible for driving process optimization, supporting production and reliability across EPS operations, packaging systems, and utilities/waste treatment areas, and ensuring safe, efficient, and compliant plant performance.
The Senior Process Engineer will lead complex technical problem-solving efforts, including root cause failure analysis (RCFA), and provide engineering leadership on capital and improvement projects. This role requires strong collaboration with operations, maintenance, EHS, and technical teams, as well as mentoring and developing junior engineers.
Position Duties/Responsibilities:
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Lead process optimization efforts across EPS manufacturing, packaging, and utilities/waste treatment systems to improve safety, reliability, throughput, and cost performance
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Serve as technical lead for complex root cause failure analysis (RCFA) investigations and implement sustainable corrective actions
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Provide day-to-day engineering support for plant operations, including troubleshooting abnormal and non-routine conditions
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Support and ensure compliance with PSM programs, including participation in PHAs, MOCs, and process safety initiatives
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Identify, develop, and execute capital and reliability improvement projects from concept through implementation
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Collaborate with operations, maintenance, and reliability teams to improve unit performance and equipment uptime
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Support process control strategies and work closely with DCS systems to optimize plant performance
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Utilize CMMS tools to support maintenance strategies, reliability improvements, and equipment history analysis
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Provide technical input for process design, operating procedures, and equipment specifications
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Interface with third-party vendors and contractors to support plant initiatives and projects
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Mentor and develop junior engineers, providing guidance on troubleshooting, process understanding, and engineering best practices
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Support production trials, product quality improvements, and process development efforts
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Participate in planned plant outages and provide off-hours support as required
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Promote a strong safety culture and ensure adherence to all safety and environmental requirements
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Perform other duties as assigned, including development and management of KPIs
Requirements:
Qualifications:
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Bachelor’s degree in Chemical Engineering (required)
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Minimum 5 years of experience in manufacturing with demonstrated success in process optimization and performance improvement
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Experience working in a PSM-covered chemical manufacturing environment
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Proven ability to lead and execute complex RCFA investigations
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Experience supporting capital and process improvement projects
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Strong troubleshooting and analytical problem-solving skills
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Experience with DCS systems (preferred)
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Experience with CMMS systems (preferred)
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Previous EPS manufacturing experience (preferred)
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Familiarity with process safety tools such as HAZOP, PHA, and MOC processes
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Strong communication, teamwork, and organizational skill
Key Attributes:
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Strong commitment to safety, compliance, and operational excellence
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Results-driven mindset with a focus on continuous improvement
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Ability to influence and drive change across cross-functional teams
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Demonstrated leadership in mentoring and developing others
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High attention to detail and ability to manage multiple priorities
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Strong technical curiosity and problem-solving mindset
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Ability to challenge assumptions constructively to achieve the best outcomes
Other Considerations:
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Physical ability to work in an industrial environment, including ability to wear PPE in designated areas (hard hat, safety glasses, FRC, safety shoes, and hearing protection), climbing stairs and ladders, willingness to work around dust, chemicals, and other
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This role is subject to the Transportation Workers Identification Credentialing rule or "TWIC" and requires a successful candidate to obtain a TWIC identification badge, allowing for unescorted access to the facility
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We are an equal opportunity employer
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This role is not eligible for work visa sponsorship
Wage and Benefits Transparency:
The final base pay offer for this position will be determined by individual factors such as location, external market factors, internal equity, and the candidate’s job-related knowledge, skills, and experience. The base salary range for this position is $100,000 to $136,000 per year.
This role is eligible for benefits, annual bonuses, and profit-sharing.
Epsilyte provides the following benefits options:
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Paid Time Off: Balance life and work with vacation and personal leave
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Family Sick Leave: Paid sick leave for absences due to illness, injury, or medical appointments of a family member; up to 40 hours per year
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Healthcare Insurance Benefits: Options for affordable medical, prescription drug, dental, and vision, along with additional insurance options within the first 30 days of hire
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Retirement Plan: 401(k) with 100% company match up to 6% of eligible compensation and a separate annual profit-sharing contribution of 5% of base salary (minimum) up to 10% based on company performance with immediate vesting
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Life and disability coverage: Company-provided short-term disability and $50,000 life/AD&D policy; LTD and additional life insurance available for you and your family
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Paid Parental Leave: Four weeks of additional paid time off with your child after birth, adoption, or foster placement, irrespective of gender
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Compassionate Care Leave: Paid and unpaid time off for bereavement following the loss of a loved one and other life-altering events
Reports to: Process Engineering & Controls Manager - Peru, IL
Who is Epsilyte?
Epsilyte LLC is one of North America’s leading producers of expandable polystyrene resin (EPS). We are a growing company of scale focused on solving customer needs for efficient, high R-value EPS. This includes reducing energy usage in buildings, ensuring safe and healthy food through innovative packaging technology, and participating in infrastructure investment both in the United States and abroad. Our vision is to improve society through our high-value, insulative products in a responsible and sustainable manner. We are headquartered in The Woodlands, Texas, with manufacturing operations in Illinois, Ohio, and Montreal, Quebec. https://epsilyte.com
About Peru, Illinois:
Peru is located in north central Illinois near the crossroads of Interstate 80 and Interstate 39, alongside the Illinois River, close to Starved Rock State Park, and 90 miles southwest of downtown Chicago. Known as the Illinois Valley, the local area contains vibrant communities and a high quality of life. Made up of 24 cities and villages in three counties, the area offers ample outdoor activities, a traditional midwestern lifestyle, and access to Chicago and all that it has. A diverse economy, low cost of living, a creative culture, and a well-educated population define the Illinois Valley. Visit www.ivaced.org for more information.
