Pilot Plant Operator

Job Title: Pilot Plant Operator

Reports to: Operations Manager

Department: Production

Location: Wasco

I. Job Description Summary:

The candidate provides technical and operational support for manufacturing and bioprocessing operations across multiple production, lab and pilot plant areas. This role is responsible for ensuring safe, efficient, and reliable operation of production equipment and processes, including fermentation, formulation, granulation, spray drying, and utilities systems. The position involves hands-on troubleshooting, preventive maintenance coordination, equipment inspections, and operator training, as well as participation in process improvements and scale-up activities. Working closely with the Operations Manager and cross-functional teams, the role supports continuous improvement, minimizes downtime, and helps maintain product quality, compliance, and operational readiness.

II. Duties and Responsibilities:

• Provide critical technical support and operational guidance for the setup, operation, troubleshooting, and maintenance of complex bioprocessing equipment including fermenters, spray dryers, evaporators, centrifuges, steam generators, and air compressors.
• Deliver hands-on training to production personnel on proper operation, assembly, and maintenance of processing equipment and components such as filters, spray dryer nozzle assemblies, pumps, valves, O-rings, gaskets, and related mechanical parts.
• Lead equipment troubleshooting, tank inspections, and overhauls by conducting root cause analysis and implementing effective mechanical or process-related corrective actions.
• Support routine production activities as well as developmental and scale-up projects, including laboratory-scale, pilot-scale, and production-scale fermentation operations.
• Execute and oversee preventive maintenance programs to ensure equipment reliability, minimize downtime, and maintain production continuity.
• Conduct daily equipment and deck inspection audits to assess mechanical integrity and operational performance; initiate corrective and preventive actions as required.
• Generate, manage, and track maintenance work orders resulting from inspections and operational needs, ensuring timely completion and verification of repairs.
• Perform daily inspections of glucose storage tanks and distribution systems to ensure mechanical integrity and prevent contamination risks.
• Manage inventory of critical production and maintenance components, including steam filters, air filters, spray dryer nozzles, valves, O-rings, gaskets, and analytical probes.
• Oversee procurement, maintenance, and service scheduling for fermenter air and steam filtration systems, including coordination with external vendors for specialized cleaning or replacement services.
• Install, calibrate, troubleshoot, and maintain dissolved oxygen (DO) and pH probes to ensure accurate monitoring and reliable process control.
• Order replacement parts, filters, and process instrumentation; negotiate with vendors to obtain competitive pricing and favorable service terms.
• Demonstrate a high level of initiative and independence by proactively identifying and implementing process improvements to enhance efficiency, quality, and operational reliability.
• Supervise special projects and assigned personnel while maintaining a positive, respectful, and safety-focused work environment.
• Work closely with the Production Manager and cross-functional departments to communicate process developments, improvements, efficiencies, and deviations

• Work Environment:

• 20% office/lab, 70% process areas under supervision and 10% pilot plant.

IV. Education/Experience:

Education

• Preferred: Associate’s degree in a technical field (e.g., Bioprocess Technology, Industrial Maintenance, Engineering Technology, or related discipline).
• Minimum Required: High School diploma or equivalent.

Experience

• Required:
  • A minimum of 10 years of hands-on experience in a plant-level fermentation manufacturing environment.
  • Extensive practical experience supporting bioprocessing operations, including fermentation, formulation, spray drying, utilities, and packaging systems.
• Preferred:
  • Demonstrated experience in project development, including process improvements, equipment upgrades, or scale-up activities.
  • Proven background in troubleshooting, preventive maintenance, equipment inspections, and operator training within a manufacturing or bioprocessing setting.
  • Experience working cross-functionally with production, maintenance, and engineering teams to support continuous improvement and operational reliability.