Senior Development Engineer

Biopolymer Technologies (BPT) is a start-up that stands at the forefront of developing and manufacturing a range of sustainable and biodegradable polymeric compounds that can help transform the way the world uses plastics. Our comprehensive suite of solutions seamlessly integrates formulation development, laboratory testing, small batch pelletizing, and full-scale production.

Position Description:

We are seeking a highly experienced Senior Process Engineer to take full ownership of our extrusion laboratory operations and contribute strategically to our product development and manufacturing scale-up efforts. This role is ideal for a hands-on processing expert who thrives in a fast-paced, flexible startup environment and wants to help build a world-class compounding operation from the ground up.

You will lead all aspects of twin-screw extrusion lab operations, including screw design changes, process optimization, formulation scale-up, and troubleshooting. You’ll work closely with our founding team and R&D scientists to convert biodegradable formulations into commercially viable products-and directly influence our scale-up to production.

This is not a lab bench role-we’re looking for someone who understands the material

and the machine, who can run trials, troubleshoot in real-time, and teach others what excellence in polymer processing looks like.

Key Responsibilities:

• Own and lead day-to-day operations of the R&D extrusion lab, including startup/shutdown, cleaning, safety, and maintenance.
  
• Change and optimize screw configurations, barrel zones, and processing parameters to suit evolving biopolymer formulations.
  
• Translate formulation intent into real-world processing conditions; diagnose and resolve processing issues such as torque spikes, melting inconsistencies, and feeding irregularities.
  
• Set up and calibrate gravimetric and loss-in-weight feeders, and ensure accurate feed ratios and throughput consistency.
  
• Collaborate with formulation scientists to interpret how fillers, plasticizers, or moisture content are affecting processing behavior.
  
• Lead and document DOE trials, develop SOPs, and build internal process knowledge for scale-up.
  
• Serve as the technical liaison between R&D and production, helping to port lab-scale successes to our commercial line.
  
• Contribute to equipment design/improvement, lab layout, and vendor selection for new tooling or auxiliary systems.
  
• Spearhead development initiatives to enhance the performance and range of our filled, biodegradable polymeric compounds.
  
• Monitor industry trends, innovations, and research to advance our understanding of these systems.
  
• Working with Operations, port new formulations and/or screw design changes to the commercial line and assist Operations with problem solving for issues encountered on the commercial line.
  
• Engage with external research bodies, academic institutions, and suppliers to foster partnerships and gain insights.
  
• Train and mentor junior engineers or technicians as the team grows.
  

Qualifications:

• 6+ years of hands-on experience in twin-screw extrusion in compounding or polymer manufacturing environments.
  
• Advanced degree in Chemical Engineering, Mechanical Engineering, Materials Science, Chemistry, Polymer Science, or a related field.
  
• Proven experience in polymer compounding, twin screw extrusion, reactive extrusion, etc., with a background in fillers and relationships between formulation and physical properties a plus.
  
• Deep understanding of extrusion process control, screw design, and material rheology.
  
• Strong working knowledge of biodegradable or biobased polymers, fillers, and polymer modifiers.
  
• Experienced in running small-lot development trials and scaling formulations to production.
  
• Familiar with moisture-sensitive materials, drying protocols, and safe handling of various additives and natural fillers.
  
• Proficient with formulation documentation, data capture, and structured process improvement methods (5 Whys, DMAIC, etc.).
  
• Comfortable working cross-functionally with R&D, operations, suppliers, and customers.
  
• Mechanical aptitude and willingness to be hands-on-changing parts, inspecting wear, and resolving mechanical and process issues.
  

Why This Role?

• You�ll own the extrusion lab-this is your domain to run, improve, and help scale.
  
• Be a core technical leader in a mission-driven startup committed to environmental impact and material innovation.
  
• Work closely with founders and decision-makers-your experience and input will shape company direction.
  
• Help build an exceptional processing environment with clean systems, traceable data, and best-in-class equipment.
  
• Competitive salary, startup equity, and leadership opportunity in a growing organization.
  

Job Type: Full-time

Pay: $100,000.00 - $135,000.00 per year

Benefits:

• 401(k)
  
• 401(k) matching
  
• Dental insurance
  
• Health insurance
  
• Paid time off
  
• Tuition reimbursement
  
• Vision insurance
  

Compensation Package:

• Bonus opportunities
  
• Weekly pay
  

Schedule:

• 10 hour shift
  
• 8 hour shift
  
• Monday to Friday
  

Experience:

• Twin Screw Extrusion: 6 years (Required)
  
• Polymer Compounding: 3 years (Preferred)
  
• Product Development: 3 years (Preferred)
  

Language:

• English (Required)
  

Ability to Relocate:

• Shelby Charter Township, MI 48315: Relocate before starting work (Required)
  

Work Location: In person