Manufacturing Engineer

Purpose of the Job

The Binder & Washwater Engineer provides technical ownership and day-to-day engineering support for binder preparation, storage, distribution, application, and associated water systems. This role ensures binder systems operate safely, reliably, and cost-effectively while meeting product quality and manufacturing performance requirements. The Binder Engineer partners closely with production, maintenance, quality, sourcing, and technical teams to troubleshoot process issues, maintain system capability, coordinate planned work, support trials and job changes, and implement sustainable process improvements.

Reports to: Plant Technical Leader

Span of Control: All chemical manufacturing processes, wool plant washwater and reclaim systems, wool plant cullet water supply

Job Responsibilities

Safety and Compliance

• Champion safe handling and use of binder chemicals and raw materials.
• Ensure compliance with required personal protective equipment, chemical hazard and, SDS/MSDS.
• Participate in area audits, risk assessments, management-of-change activities, and development of safe standard work.
• Identify and address process, equipment, environmental, and chemical-handling risks.

Binder Chemistry and Formulation

• Develop a working understanding of binder components and their function within the formulation.
• Monitor and adjust binder solids, pH, ingredient ratios, LOI, BAE, and other critical parameters.
• Evaluate the effects of formulation and process changes on binder performance, product quality, and manufacturing cost.
• Support recipe development, formulation changes, and raw-material conversions.

Binder Mix System Operation and Control

• Provide technical support for automatic and manual binder mixing systems.
• Coordinate and support calibration mixes, routine production mixes, job-change mixes, and recipe changes.
• Configure and maintain binder recipes, ingredient parameters, tank parameters, and system operating settings.
• Use HMI, PLC, OnSpec, PanelView, mass-flow meter, and process-reporting information to monitor system performance and respond to alarms.
• Work with controls and electrical resources to improve system reliability and address instrumentation issues.

Storage, Transfer, Filtration, and Application

• Provide process ownership for binder storage tanks, circulation tanks, transfer systems, filtration equipment, pumps, valves, and associated piping.
• Ensure adequate binder flow and pressure to the forehearth and application systems.
• Monitor filtration performance and coordinate filter changes, pump inspections and valve work.

Water and Reclaim Systems

• Provide technical support for wash water, wash water neutralization, and reclaim systems.
• Monitor and optimize reclaim-water solids and reuse rates.
• Support bacterial control, pH management, system cleaning, and water-treatment activities.
• Coordinate technical needs with water-treatment suppliers and internal operating and maintenance teams.

Quality and Process Monitoring

• Monitor binder solids, pH, cleanliness, ingredient ratios, temperatures, pressures, flow rates, LOI, BAE, and other key process measures.
• Interpret laboratory results, inline refractometer readings, free-formaldehyde testing, and process trends.
• Investigate abnormal conditions and establish appropriate corrective actions.
• Maintain process-control documentation, calibration records, audit results, and performance dashboards.
• Use IP21, Seeq, SQL, or comparable process-data tools to identify trends and improvement opportunities.

Troubleshooting and Root-Cause Analysis

• Serve as a primary technical resource for binder-system and related production issues.
• Diagnose abnormal solids or pH, high reclaim-water solids, low reuse, low binder pressure, flow interruptions, and equipment-control problems.
• Lead or support structured root-cause analysis.
• Implement corrective actions and monitor results to verify that improvements are sustained.
• Provide timely technical support for operator calls, process upsets, trials, and production interruptions.

Maintenance and Work Coordination

• Develop and maintain priorities for binder-related maintenance work.
• Create notifications or work requests and follow items through completion.
• Support coordination of planned cleanings, inspections, calibrations, filter replacements, valve repairs, and preventive-maintenance activities.
• Verify completed work meets operational and technical requirements.
• Coordinate production, maintenance, electrical, contractor, and vendor activities to minimize disruption to manufacturing.

Process Improvement and Cost Management

• Identify and execute projects that improve safety, quality, reliability, waste, productivity, and operating cost.
• Understand the binder cost model and the economics of solids recovery and reclaim-water reuse.
• Develop technical and financial justification for improvement opportunities.
• Support capital projects, process trials, equipment redesigns, and new-material implementation.
• Follow applicable project-management, change-management, stage-gate, and management-of-change processes.

Training and Standardization

• Develop and maintain standard work, job breakdown sheets, troubleshooting guides, operating procedures, and training materials.
• Train operators, maintenance employees, and technical personnel on binder chemistry, equipment, controls, and operating expectations.
• Coach others in troubleshooting and process decision-making.
• Build organizational capability by documenting system knowledge and lessons learned.

Expected Proficiency

The successful Binder Engineer should be able to:

• Independently perform normal binder-system engineering responsibilities.
• Lead troubleshooting and corrective-action activities.
• Coach operators and technical partners.
• Interpret process, laboratory, quality, and equipment data.
• Modify recipes and operating parameters through approved processes.
• Develop training, specifications, and technical standards in assigned areas.
• Progress toward subject-matter-expert capability in process improvement, cost optimization, and binder-system design.

Minimum Qualifications

• Bachelor’s degree in chemical engineering, mechanical engineering, electrical engineering, manufacturing engineering, or a related technical discipline.
• Manufacturing or process-engineering experience in chemical mixing, liquid-delivery systems, process controls, or continuous manufacturing.
• Experience with PLC/HMI systems, process historians, data-trending tools, and structured root-cause analysis.
• Ability to work safely around industrial chemicals, operating equipment, elevated temperatures, pumps, tanks, and piping systems.
• Strong written and verbal communication skills with the ability to work effectively across production, maintenance, quality, laboratory, sourcing, and leadership teams.

Measures of Success

• Safe and compliant operation of binder and associated water systems.
• Stable binder solids, pH, flow, pressure, and ingredient mixing.
• Effective response to process upsets and equipment issues.
• Reduced binder-related downtime, waste, and recurring failures.
• Accurate recipes, calibrations, audit records, and technical documentation.
• Successful execution of trials, job changes, maintenance activities, and improvement projects.
• Improved binder cost, solids recovery, and reclaim-water performance.
• Increased operator and maintenance capability through effective training and coaching.

About Owens Corning  

Owens Corning is a branded building products leader with three complementary market-leading businesses providing roofing, insulation, and doors primarily for residential markets in North America and Europe. The company operates with an integrated go-to-market strategy and a unique set of OC Advantages™ – including its iconic brand, unparalleled commercial strength, leading technology, and winning cost position – to help customers win and grow in the market. Owens Corning is committed to helping build better and achieve more through winning partnerships, leading performance, and engaging people. Founded in 1938 and headquartered in Toledo, Ohio, Owens Corning is listed on the New York Stock Exchange (NYSE: OC). For more information, visit www.owenscorning.com.

Owens Corning is an equal opportunity employer. Except in limited circumstances such as formal apprenticeship programs, Owens Corning does not employ anyone under the age of 18.