Senior Process Development Engineer Jobs in Milwaukee, WI

About Us & Position Summary

Microbial Discovery Group, a vital subsidiaryof United Animal Health, is an R&D-driven product development and Bacillus fermentation company. We apply Real Science to a Trusted Process, yielding Proven Success for our partners. At MDG, we recognize the need for sustainable solutions to the world's largest problems, and we work to solve them as part of our mission to Feed, Clean, Save the World. As a member of our team, your ideas and innovations are integral to who we are. Come grow with us!
As a Process Development Specialist II, you will play a key role in advancing our fermentation technologies and translating scientific innovation into scalable solutions for our customers. You will preform laboratory-based process development activities focused on microbial fermentation using bench-scale bioreactors. Design, execute, and optimize fermentation experiments; operate and troubleshoot bioreactor systems; and analyze process data to support scale-up, robustness, and overall process performance. Collaborate cross-functionally to enable effective technology transfer and contribute to a strong safety and quality culture in the lab.

Key Responsibilities

Plan, execute, and monitor microbial fermentation processes in 1-10L bioreactors, including set-up, inoculation, operation, harvest, cleaning, sterilization, and routine maintenance.

Independently troubleshoot bioreactor systems (e.g., pH, dissolved oxygen, temperature, agitation, gas flow) to maintain consistent performance and product quality.

Prepare media, buffers, and inoculum using aseptic techniques and established SOPs.

Design and execute experiments to evaluate and optimize process parameters for yield, scalability, robustness, and cost-effective raw material utilization.

Collect, analyze, and interpret in-process samples (e.g., OD, cell counts, metabolite concentrations) to monitor fermentation performance.

Utilize analytical methods, such as spectrophotometry and HPLC or similar techniques, to assess process outcomes and product quality attributes.

Interpret process data to identify trends, deviations, and process limitations (e.g., oxygen transfer, substrate inhibition, byproduct formation) and recommend actionable improvements.

Support scale-up activities by translating lab-scale results into pilot-scale recommendations, including mixing, kLa, and heat transfer considerations.

Document experimental plans, methods, data, and conclusions in a clear, timely, and compliant manner to ensure reproducibility and effective technology transfer.

Collaborate with upstream, downstream, analytical, and operations teams to align on process development strategies and timelines.

Adhere to all laboratory safety procedures, biosafety and chemical handling guidelines, and applicable internal quality standards.

Support occasional non-routine or off-shift work hours as needed to initiate, monitor, or complete critical fermentation runs.

Additional Responsibilities

Provide ad hoc experimental support, data analysis, and troubleshooting to address urgent technical questions or investigation needs.

Contribute to continuous improvement of lab operations, including updating SOPs, enhancing workflows, and implementing best practices for bioreactor operation and maintenance.

Assist with onboarding and informal mentoring of new team members on equipment operation, safety practices, and documentation standards.

Participate in cross-functional meetings and project reviews, presenting experimental results and process recommendations as needed.

Work Environment

Laboratory-based, indoors, in an environmentally controlled setting with regular exposure to biological materials and chemicals.

Requires routine use of personal protective equipment (PPE) and adherence to biosafety and chemical safety practices.

Combination of hands-on work at the bench/bioreactors and computer-based data analysis and reporting.

Requires standing for extended periods and occasional lifting or movement of equipment and supplies (up to approximately 50 lbs) following safe ergonomic practices.

Minimum Qualifications

Bachelor's degree in microbiology, biotechnology, biochemical/chemical engineering, or a related field; or equivalent practical experience in microbial fermentation.

Hands-on experience operating microbial fermentation and bench-scale bioreactor systems.

Familiarity with aseptic techniques, microbial cultivation, and standard laboratory practices.

Working understanding of microbial physiology, fermentation kinetics, and core process principles.

Experience designing and analyzing experiments; exposure to Design of Experiments (DOE) is a plus.

Proficiency with basic data analysis tools (e.g., Excel, JMP, or similar) and ability to interpret process data.

Strong attention to detail and ability to follow written protocols, SOPs, and safety procedures.

Preferred Qualifications

Experience with automated bioreactor systems (e.g., Sartorius, Applikon, Eppendorf) and associated control software/data acquisition tools.

Practical knowledge of developing and optimizing batch and fed-batch strategies, including carbon feeding, nitrogen control, and oxygen transfer management.

Experience with scale-up or tech transfer, including understanding of oxygen transfer, mixing, and feeding challenges at larger scales.

Experience working with industrial microbial strains and complex media formulations.

Awareness of downstream processing considerations and how fermentation performance affects separation, concentration, and drying processes.

Technical Skills

Operation, set-up, and troubleshooting of bench-scale bioreactors and associated control systems.

Aseptic technique, microbial cultivation, and preparation of media, buffers, and inoculum.

Use of analytical methods such as spectrophotometry and HPLC or similar technologies.

Data analysis and visualization using tools such as Excel, JMP, or comparable software.

Non-Technical Skills

Strong organizational skills with the ability to manage multiple experiments and priorities.

Effective written and verbal communication, including clear documentation of methods and results.

Ability to work both independently and collaboratively within cross-functional teams.

Adaptability, problem-solving mindset, and commitment to continuous improvement.

Licenses/Certifications

None required.

Physical & Safety Requirements

Ability to work in a laboratory environment with biological materials and chemicals while wearing appropriate PPE.

Ability to stand for extended periods and lift/move laboratory equipment and supplies (up to approximately 50 lbs) with proper technique.

Disclaimer

Adherence to all food safety procedures as per FDA regulations, including the FDA Food Safety Modernization Act (FSMA) or any other applicable federal, state, or local food safety regulations.