[Hiring] Process & Controls Engineer @LGI Homes

Role Description

The Process & Controls Engineer will support the design, optimization, and continuous improvement of production processes within the Proliant Dairy manufacturing sites. This role works cross functionally with operations, quality, maintenance, and corporate teams to:

• Increase throughput
• Reduce waste
• Improve product quality
• Reduce energy usage
• Ensure regulatory compliance

Qualifications

• Bachelor’s degree in Electrical Engineering, Food Engineering, Mechanical Engineering, or related discipline.
• Minimum 2 years of experience in the food or beverage manufacturing environment, ideally dairy.
• Strong understanding of unit operations: thermal processing, evaporation, drying, filtration, separation, pumping, CIP and sanitation.
• Working knowledge of FDA/USDA regulations and food safety systems.
• Proficiency in data analysis tools (Excel, Power BI, Minitab, or similar).
• Familiarity with Allen-Bradley's ControlLogix 5000 programming software and/or Ignition.
• Experience with Dairy processes, including evaporation, drying and membrane filtration (UF/RO/NF), or spray drying (preferred).
• Lean/Six Sigma Green Belt or Black Belt certification (preferred).
• Experience working in high-volume Dairy processing environments (preferred).
• Familiarity with AutoCAD, or other process modeling tools (preferred).
• Strong project management experience (preferred).

Requirements

• This role may be fully remote when not traveling, with regular travel to company manufacturing sites (approximately 60%).
• Candidates located within driving distance of Melrose, MN or St Johns, MI are preferred.
• Strong analytical and problem-solving skills.
• Ability to lead cross-functional teams and influence without authority.
• Excellent communication—both technical and operational.
• Continuous improvement mindset with a focus on safety and quality.
• Hands-on, plant-floor-focused approach.
• Ability to travel and work at company facilities for extended hours as needed. Expected travel at least 60%.
• Ability to work independently with minimal supervision.

Job Duties

• Analyze, develop, and optimize unit operations such as evaporation, drying, filtration, membrane processing, and thermal treatment.
• Conduct time, yield, and mass‑balance studies to identify inefficiencies and implement solutions.
• Lead continuous improvement initiatives using Lean, Six Sigma, or similar methodologies.
• Support capacity expansion projects by providing process calculations, equipment specifications, and line balancing.
• Create, edit, and update Process Instrumentation Diagrams (P&IDs) in alignment with engineering and operational requirements.
• Identify and implement process improvements that reduce energy consumption, improve thermal efficiency, and lower utility costs.
• Provide input and expertise for Dairy processing technologies, including equipment CIP, Process improvement via equipment optimization.
• Collaborate with R&D to scale new products—from bench to pilot to full commercial scale.
• Troubleshoot process deviations and performance bottlenecks.
• Utilize statistical tools to track process KPIs such as yields, moisture, solids content, viscosity, and other key process metrics.
• Interpret manufacturing data to make recommendations for efficiency improvement or quality enhancement.
• Support implementation and refinement of MES/SCADA systems for process monitoring.
• Ensure all processes comply with HACCP, USDA, FDA, and SQF/BRC requirements.
• Maintain documentation including process flow diagrams (PFDs), SOPs, and control plans.
• Work with QA to resolve customer complaints, deviations, and audit findings.
• Assist with equipment evaluation, FAT/SAT testing, commissioning, and startup.
• Manage small‑to‑medium capital projects, including scope, budget, timeline, and contractor coordination.