The Molded Fiber Process Engineer - Stock Prep & Pulp Systems is responsible for the fiber, stock approach, and pulp chemistry behind Genera's molded fiber product development program. This role optimizes fiber preparation, refining, and stock delivery to enable new product formulations, grade development, and performance targets - working hand-in-hand with Product Development, R&D, Quality, and Operations rather than steady-state mill production alone.
This engineer translates product performance requirements (strength, formation, OGR, water resistance, moldability) into fiber and stock specifications, then runs the trials, pilot work, and process characterization needed to bring new molded fiber products from concept to commercial-ready process conditions.
KEY RESPONSIBILITIES
Fiber & Stock Development for New Products
- Develop fiber blends, refining targets, and stock approach conditions to meet new product performance requirements
- Translate product development briefs (strength, formation, runnability, OGR, stiffness, moldability) into pulp and stock specifications
- Run bench-, pilot-, and mill-scale trials to characterize new fiber furnishes and molded fiber formulations
- Own fiber-side scale-up from lab/pilot trials into production-ready process windows
Process Optimization & Control
- Monitor and optimize pulping, washing, screening, cleaning, refining, and stock prep systems in support of product trials and commercial grades
- Improve fiber yield, freeness, strength properties, and consistency control across trial and production runs
- Reduce variability through improved operating windows, SOPs, and control strategies for new and existing furnishes
- Analyze process data to identify losses, bottlenecks, and quality risks tied to product performance
Cost, Yield & Energy Improvement
- Drive reductions in fiber loss, chemical consumption, water usage, and energy intensity as new formulations move to scale
- Identify and implement variable cost reduction initiatives for fiber and stock prep systems
- Support benchmarking and best-practice deployment across mill and product development operations
Quality & Product Performance
- Partner with Quality and Product Development to ensure pulp and stock meet performance targets (strength, formation, runnability, OGR, stiffness, etc.)
- Support root-cause analysis of customer complaints and internal quality deviations tied to fiber or stock
- Lead the fiber/pulp workstream for grade changes, product trials, and new product introductions
Troubleshooting & Continuous Improvement
- Use Lean / Six Sigma green or black belt methodology for structured problem solving
- Support up-time improvement by addressing process-related reliability challenges affecting trials and production
- Serve as a technical resource during upsets, startups, shutdowns, and trial runs
Capital Projects & Technical Support
- Provide process design input for capital projects and equipment upgrades tied to stock prep and pulp systems
- Support commissioning, startup, and post-startup optimization for new or modified fiber/stock equipment
- Develop process specifications, mass balances, and performance criteria for new product platforms
Safety & Environmental Compliance
- Champion safe operating practices and MOC discipline
- Ensure processes comply with environmental permits and regulations
- Identify opportunities to reduce emissions, effluent load, and waste
QUALIFICATIONS
Required
- Bachelor's degree in Chemical Engineering, Pulp & Paper Engineering, or related discipline
- 3+ years of experience in a pulp mill, fiber prep, or paper/packaging operation
- Strong understanding of pulping, stock prep, refining, and fiber quality drivers
- Data-driven mindset with strong analytical and problem-solving skills
- Ability to work effectively on the plant floor with operators and technicians, and cross-functionally with Product Development and R&D
Preferred
- Experience with recycled fiber or non-wood fiber (e.g., molded fiber, ag pulp, bagasse, wheat straw)
- Experience supporting thermoforming, paper, or molded fiber downstream processes
- Prior involvement in new product development or product trial work, not solely steady-state operations
- Lean Manufacturing / Green Belt or Black Belt certification
- Experience with Minitab
- Familiarity with DCS/PLC systems, SPC, and process modeling
KEY SUCCESS METRICS
- Successful execution of fiber/stock trials and new product introductions
- Fiber yield improvement
- Reduction in variable cost per ton
- Process stability and uptime during trials and production runs
- Pulp and stock quality consistency against product performance targets
- Successful execution of capital projects supporting product development
- Safety and environmental performance