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Candidate Details

Name :

Joseph Mirus
Qualification :
Process Engineer
Industry :
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Candidate ID:
JM332
This candidate has been hired.

Process Engineer

About our Client

Accomplished and results-driven Process Engineer with over a decade of experience across diverse industries, including energy, food science, and beverage manufacturing. Expertise in developing and optimizing manufacturing processes, with a proven track record of driving significant improvements in efficiency, cost reduction, and product quality. Skilled in statistical analysis, design of experiments, and root cause analysis, consistently solving complex technical challenges to deliver high-impact results. Adept at managing cross-functional teams, leading product scale-up from bench-top to full production, and fostering collaboration across various business functions. Demonstrated success in creating innovative solutions to complex problems, such as optimizing plasma reactor processes, improving product flow properties, and managing large-scale commercialization efforts. Passionate about continuous improvement, safety, and fostering team-driven success.

Achievements

Statistical Data Analysis: Proficient in JMP, MiniTab, and Excel, with hands-on experience in conducting Design of Experiments (DoE) and Process Capability Analysis to optimize production processes.

Process Optimization: In-depth knowledge of plasma reactor design and powder dispersion processes, with a successful track record in improving process effectiveness by 39% through factorial design of experiments.

Certification in Sensory Evaluation: Certified by the Coffee Quality Institute in sensory evaluation, ensuring a comprehensive understanding of coffee quality and sensory testing methodologies.

Project Management: Exceptional leadership skills demonstrated through the successful management of cross-functional teams to scale up products from bench-top to full production at both internal and external manufacturing sites.

Problem Solving: Strong analytical and problem-solving abilities, as evidenced by solving complex processing challenges during high-profile product launches, preventing a potential loss of a key client.

Team Leadership: Proven ability to lead and motivate teams, as demonstrated by managing and mentoring technicians, while fostering collaboration and driving continuous improvement in process efficiency.

Professional Experience

Process Engineer

  • Created new processes and hardware for the manufacture of battery material powders on the UniMelt microwave plasma reactor.
  • Optimized the plasma reactor for specific materials using factorial design of experiments.  This increased the effectiveness of one process from 54% to 93%.
  • Developed a real time estimate of the process effectiveness using Mass Spectrometry which allowed for an acceleration of our experimentation.
  • Solved a powder dispersion problem for the feed system.
  • Developed methods of granulating cathode powders to optimize downstream operations.
  • Managed the daily activities of a technician.
  • Member of the safety committee identifying hazards and addressing them.

Senior Process Engineer / Commercialisation Manager

  • Saved a business relationship by solving many processing problems for a high-profile product launch. This involved an extensive Root Cause Analysis across many unit operations.  The customer went from being ready to abandon the project due to doubts about our process capability to increasing the market test order.
  • Managed a commercialization team responsible for scaling up products at co-manufacturers.
  • Provided statistical support for other projects.

Independent Consultant

  • Formulated powdered beverages and defined processes for a company wanting to bring formulation and production in-house.

Process Engineer

  • Scaled up and commercialized 16 new products.
  • Formulated a coffee plus creamer beverage that had to function in the constraints of the Keurig brewing platform.
  • Saved $6 million annually through coffee processing optimization and continuous improvement projects.
  • Worked with co-manufactures to ensure that product and processing specifications were met.
  • Increased processing performance of many powdered products by manipulating physical properties of the product and optimizing equipment.
  • Increased measurement capabilities of the production plants to keep products within specification.
  • Conducted shelf-life studies that evaluated both sensory attributes and product functionality.
  • Solved powder flowability and segregation problems.
  • Validated powder blending at scale.
  • Wrote Standard Operating Procedures for new processes.

Pilot Plant Assistant Manager

  • Performed various processing trials including aseptic, retort, homogenization, freeze drying, drum drying, spray drying, and more.
  • Built food processing systems for classes, student projects, and the Aseptic Processing and Packaging Workshop.
  • Supervised student workers.

Education

Bachelor of Science – Major in Food Science

Interests

Skills

Technical Skills

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