Associate Downstream Process Development Scientist Jobs in Virginia

Manufacturing Process Engineer – Non-Woven (TSE)

Danville, VA
Reports to Department Manager www.bgf.com

About BGF Industries

BGF Industries is a leading U.S. manufacturer of innovative technical fiber materials used worldwide in aerospace, marine, automotive, filtration, insulation, electrical, and protective markets. Since 1941, BGF has built a reputation for engineering excellence, product integrity, and continuous innovation.

Headquartered in Danville, Virginia, with multiple manufacturing facilities across Virginia and South Carolina, BGF delivers advanced fiber-based solutions that meet demanding performance standards for strength, heat resistance, and durability.

Our mission is simple but powerful:

“Deliver excellence in every product, every process, every time.”

Position Overview

The Process Engineer’s role is critical to ensuring that BGF’s nonwoven manufacturing operations run safely, reliably, and efficiently, delivering consistent product quality while fostering continuous improvement. This individual will provide technical expertise in process development and troubleshooting, work cross-functionally with R&D, quality, production, and customers, and help drive innovation in nonwoven mat technologies and manufacturing methods.

1. *Collaborate with internal teams (R&D, Quality, Sales/Marketing, Operations) and customers to define, refine, and document product and process specifications.
2. *Support business and technical strategy by evaluating emerging nonwoven, fiber, adhesive, film, and bonding technologies and recommending adoption or trials.
3. Represent BGF at industry conferences, technical symposiums, and trade fairs; maintain networks with suppliers, academic institutions, and technology providers.
4. Provide direct technical support to customer sites as needed, assisting in performance troubleshooting or process optimization.
5. Monitor and evaluate new materials (fibers, binder systems, films, additives) and associated equipment/technologies; coordinate vendor interactions for trials or supply.
6. *Recommend and implement process improvements (throughput, waste, cost, quality control) via modifications, controls, or process redesigns.
7. Work hands-on with production operators to diagnose and resolve processing issues (web break, fiber migration, defects, tension control, bonding issues).
8. *Collaborate with Quality and Customer Service to investigate, root-cause, and respond to customer claims or quality incidents.
9. *Design, execute, and analyze experiments (Design of Experiments / DOE) and statistical analyses to optimize process parameters.
10. Plan, coordinate, and oversee plant trials; collect, validate, and interpret experimental data.
11. Analyze results, draw actionable conclusions, and present findings (written reports, trend charts, visualizations, oral presentations).
12. Assist in the selection, specification, procurement, and implementation of new or upgraded process equipment and instrumentation.
13. Ensure safe working practices, adherence to EHS standards, and continuous safety improvement in assigned areas.

1. Perform supporting tasks as assigned by management, including:
   a. Create or maintain cost capture / throughput models and item setups in production systems.
   b. Develop and document new process setups, standard operating procedures (SOPs), and transfer-to-production documentation.
   c. Provide technical feedback or guidance to customers as applicable.

Qualifications & Experience

Education

• Bachelor’s degree (B.S.) in Chemical Engineering, Materials Science, Textile Engineering, Mechanical Engineering, or a closely related discipline
• Advanced degrees (M.S., M.Eng) or specialization in nonwovens/textiles are a plus

Experience

• 1–5 years (or equivalent via co-op/internship) in process engineering or technical roles, preferably in nonwoven, fiber, textile, or related process industries
• Hands-on experience with industrial nonwoven processes (needling, bonding, laminating, slitting, winding, coating) is highly desirable
• Demonstrated experience with DOE, statistical process control (SPC), root-cause analysis, and data-driven decision-making

Skills & Competencies

• Proficiency with DOE methodologies and statistical / data analysis tools (Minitab, JMP, R, Python, or equivalent)
• Sound process fundamentals (mass/heat balance, fluid flow, tension control, web handling)
• Strong technical troubleshooting, analytical, and problem-solving skills
• Ability to create and deliver clear technical reports, visualizations, and presentations
• Excellent interpersonal skills and ability to work cross-functionally with production, R&D, quality, and customers
• Self-motivated, detail-oriented, and results-driven
• Familiarity with process instrumentation, sensors, control systems (e.g., temperature, tension, pressure)
• Understanding of quality systems (ISO 9001), process documentation, change control

Other Requirements / Certifications

• Ability to work in a manufacturing environment, use necessary personal protective equipment (PPE)
• Must pass company medical / health assessments
• Some travel to customer sites or conferences may be required

Working Conditions & Physical Demands

• The role requires frequent walking, standing, bending, stooping, climbing, crawling, reaching, grasping, and occasionally lifting (up to ~50 lbs, with assistance/mechanical aids)
• Use of hands/fingers for data entry, instrumentation interaction, manual adjustments
• Ability to work in variable manufacturing environments, including areas with fiberglass, dust, fiber particles, or chemical exposure. PPE (respirators, hearing protection, gloves, etc.) is mandatory in designated zones
• Annual hearing tests (audiograms) as per company policy

Key Performance Indicators (KPIs) / Metrics of Success

• Improvement in process yield, throughput, and reduction in defects / waste rates
• Successful completion of assigned plant trials, technology initiatives, and optimization projects
• Responsiveness and resolution of processing issues / customer claims
• Quality of experimental design, data analysis, and clarity of technical reporting
• Safety performance and compliance within assigned areas
• Effective collaboration with cross-functional teams (R&D, production, quality, sales)

Organizational Relationships

• Reports to: Plant Manager (Altavista)
• Dotted-line to: VP of R&D / Technical Support
• Interfaces with: R&D / Lab, Quality / QC, Operations / Production, Sales / Marketing, Supplier / Vendor contacts, Customer technical teams

Why Join BGF?

• Be part of a technology-driven company leading in technical fiber and nonwoven materials, with a culture of innovation and continuous improvement
• Work in a facility focused on advanced nonwoven mat manufacturing and support cutting-edge product development for high-temperature insulation, acoustics, filtration, and specialty applications
• Collaborate across disciplines and with customers in a dynamic environment that encourages technical growth, cross-training, and leadership opportunities
• Contribute meaningfully to continuous improvement, process innovations, cost reductions, and product quality enhancements

Why Join BGF Industries?

• Competitive compensation and comprehensive benefits
• Opportunities for growth and leadership within a global organization
• A stable, values-driven company culture emphasizing integrity, teamwork, innovation, and excellence
• The ability to make a tangible impact in a growing, technology-focused manufacturing environment

This position requires access to information or technology that is subject to U.S. export control laws, including the International Traffic in Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). Pursuant to these regulations, only U.S. Persons (U.S. Citizens or Lawful Permanent Residents/Green Card holders) are eligible for this role. Proof of U.S. Person status will be required prior to employment.