Process Engineer

Overview

Buzzi Unicem USA is one of the leading cement manufacturing companies in the United States.  With over 1,500 valued employees, Buzzi Unicem USA manufactures and distributes its cement products throughout the Midwest, Southwest, Northeast and Southeast regions of the country.  Globally, Buzzi Unicem SpA operates in 14 countries and employs almost 10,000 people. We are passionate about sustainably producing our cement products for the benefit of society by providing the foundation for crucial infrastructure projects such as roads, bridges, tunnels, airports, dams, and residential and industrial buildings. 

Our commitment to positively contributing to society is a core principle for our business, and the reason we focus heavily on sustainable development. As part of our corporate culture, we recognize our role in meeting the current generation’s needs, while preserving environmental quality and protecting the needs of future generations.

Additionally, quality serves as the foundation of the way we do business at Buzzi Unicem USA.  We have established at all our production sites, quality targets for our products that meet not only local regulatory standards but also our customer requirements.

Buzzi Unicem USA strives to provide a corporate culture supporting career growth through strong leadership and development planning.   We offer a competitive salary, along with comprehensive medical, dental, and vision benefits. Plus, our benefits include flexible spending accounts, supplemental life insurance and other voluntary benefits – such as accident and critical illness. We also provide a 401(k) savings plan, Employee Assistance Program, a tuition reimbursement program, professional development and advancement opportunities.

Join our team, be part of the solution, support evolving innovations, and help us continue providing quality products, all while being supported by strong leadership and a comprehensive and competitive benefits program.

Responsibilities

The Process Engineer leads process improvement efforts for critical cement manufacturing systems, including kilns, raw mills, finish mills, and material handling operations. This role is responsible for driving operational efficiency, product quality, cost reduction, and environmental performance through data-driven process optimization.

• Monitor and analyze plant operations to optimize process performance and reduce energy consumption (Fuel and electric Power).
• Assist in implementing process control strategies and automation improvements.
• Drive optimization initiatives with quality, maintenance, and operations teams to achieve production goals.
• Ensure compliance with company safety standards, environmental regulations, and maintenance best practices.
• Prepare technical reports and performance summaries for optimization projects using tools such as process and equipment audits, material sampling, and heat, material, and power balance analysis.
• Develop and review standard operating procedures (SOPs).
• Lead and support troubleshooting, Root Cause Failure Analysis (RCFA), and continuous improvement initiatives to identify, resolve, and prevent process upsets and equipment failure.
• Assist in commissioning and testing of new process equipment.
• Support environmental compliance and sustainability initiatives.
• Train operators on process understanding and data interpretation.
• Participate in capital project planning and process design evaluations.

Qualifications

Qualifications

• Must be at least 18 years of age and legally authorized to work in the United States.
• This is a safety-sensitive position requiring compliance with all company safety policies, OSHA/MSHA regulations, and applicable drug and alcohol testing requirements.
• Ability to communicate effectively in English, both verbally and in writing.
• Strong analytical, problem-solving, and organizational skills with the ability to evaluate complex process data and drive continuous improvement.
• Solid understanding of cement manufacturing processes, cement chemistry, clinker quality, and process optimization principles.
• Ability to manage multiple priorities, projects, and deadlines in a fast-paced manufacturing environment.

Education & Experience

• Bachelor's degree in Chemical Engineering, Mechanical Engineering, Industrial Engineering, or a related engineering discipline required.
• 2-5 years of process engineering, production engineering, or industrial manufacturing experience preferred; cement or heavy industrial experience is a plus.
• Knowledge of thermodynamics, fluid mechanics, combustion systems, heat transfer, and process optimization principles.
• Experience with process data management, industrial analytics platforms, historians, digital dashboards, or predictive analytics tools.
• Familiarity with PLCs, DCS, HMI systems, process controls, and industrial automation technologies.
• Working knowledge of industrial processes, emissions control systems, and failure analysis methodologies.

Skills & Competencies

• Demonstrated commitment to safety leadership and operational excellence.
• Experience utilizing advanced process monitoring and analytics tools to analyze production performance, identify trends, and improve plant efficiency.
• Ability to optimize kiln, mill, material handling, combustion, and related manufacturing processes to improve reliability, throughput, and energy performance.
• Strong understanding of statistical analysis, process capability, and statistical process control (SPC) concepts.
• Ability to lead process audits, identify bottlenecks, and implement sustainable process improvements.
• Effective communication and collaboration skills with operations, maintenance, quality, environmental, and management teams.
• Knowledge of process automation, control loops, instrumentation, and advanced process control systems.

Technical Knowledge

• Familiarity with environmental permits, emissions monitoring systems, and regulatory compliance requirements.
• Understanding of maintenance work management systems, purchasing processes, and operational reporting tools.
• Knowledge of process control systems, instrumentation, sensor technologies, and DCS/PLC architectures.
• Experience analyzing operational and quality data to improve product consistency, process stability, environmental performance, and overall plant efficiency.

We are an equal opportunity employer and consider all qualified applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, veteran status, or other protected characteristics.