Process Development Engineer - Crystallization, Drying & Powder Processing

Stellenbeschreibung:

Process Development Engineer - Crystallization, Drying & Powder Processing

Primogene GmbH is an innovative biotech company developing advanced bioprocesses for the production of functional ingredients. We support human health through all stages of life and across industries including nutrition, pharma, and personal care.

We are seeking a highly motivated Process Development Engineer to lead the development, optimization, and scale‑up of formulation and drying processes mainly for sugar and carbohydrate-based ingredients. In this role, you will design and integrate drying and crystallization strategies, define key process parameters, and solve complex formulation challenges to deliver stable, high-quality powders at commercial scale. You will work closely with upstream fermentation, downstream purification, and product development colleagues to ensure integrated process development.

Key responsibilities

Develop, optimize, and scale up drying and crystallization processes for sugars and carbohydrate-based ingredients, including oligosaccharides and sugar derivatives.
Select and define the most suitable drying and crystallization technologies (e.g., spray drying, freeze drying/lyophilization, vacuum drying, fluidized bed drying) based on product properties, process requirements, and commercial objectives.
Design, integrate, and implement drying and crystallization steps within the downstream processing (DSP) workflow, ensuring seamless transition from upstream and purification stages.
Establish and optimize critical process parameters – including temperature profiles, atomization pressure, feed concentration, chamber pressure, supersaturation, nucleation, and residence time – to achieve desired product attributes such as particle size, moisture content, stability, and morphology.
Address formulation and process challenges (e.g., stickiness, hygroscopicity, crystallization behavior, thermal sensitivity) and propose technical solutions to improve product quality and process robustness.
Implement post-processing strategies such as secondary drying, conditioning, agglomeration, coating, and milling to enhance powder properties, shelf life, and overall product performance.
Perform troubleshooting, root‑cause analysis, and continuous process optimization to resolve technical issues and drive performance improvements.
Support equipment selection, commissioning, qualification, and scale-up for new drying and crystallization installations, contributing to CAPEX/OPEX planning and process economics assessments.
Apply Quality-by-Design (QbD) principles to establish robust control strategies, ensuring consistent product quality and process reliability.
Work closely with upstream fermentation, downstream purification, and product development teams to achieve integrated process development and commercial‑scale manufacturing.

Qualifications

Education & Experience

Education in Chemical Engineering, Bioprocess Engineering, Food Technology, Pharmaceutical Technology, or a related field.
Industry experience in process development, scale‑up, or manufacturing, ideally focused on drying, crystallization, or powder formulation.
Proven track record in developing and optimizing spray drying, freeze drying, vacuum drying, or fluidized bed drying processes.
Hands‑on experience with carbohydrate-based products, oligosaccharides, biopolymers, or bio-based ingredients is a strong plus.

Technical Skills

Strong knowledge of drying and crystallization principles, phase behavior, thermodynamics, and mass/heat transfer.
Experience defining and optimizing critical process parameters to achieve target product properties.
Familiarity with powder engineering aspects such as particle size distribution, flowability, morphology, and moisture control.
Experience with post-processing operations (e.g., agglomeration, coating, milling) and product stability enhancement.
Competence in process design, scale‑up, and techno‑economic evaluation (CAPEX/OPEX).

Soft Skills & Mindset

Pragmatic and strong problem-solving and analytical skills, with the ability to perform root cause analysis and continuous process improvement.
Excellent cross‑functional collaboration skills, with experience working closely with upstream, downstream, and product development teams.
Hands‑on, proactive, and entrepreneurial mindset suited for a fast‑paced, innovation-driven environment.
Strong communication skills, both written and verbal, in English (German is a plus).