Summary

The Pilot Plant Manager leads the operation, safety, capability development, and continuous improvement of the pilot plant facility to enable efficient product development, process scale-up, and commercialization. This role bridges R&D, Operations, Quality, and Engineering to ensure that bench formulations translate effectively to scalable, manufacturable products.
This leader ensures the pilot plant operates as a high-performing, technically sound, and strategically aligned capability that supports innovation, renovation, and commercialization priorities.

Responsibilities

• Pilot Plant Operations & Execution
• Oversee daily pilot plant operations, scheduling, and resource allocation.
• Ensure safe, compliant operation of all processing equipment (HTST, homogenizer, separators, retort, etc.).
• Manage batch execution for product development, scale-up trials, and validation runs.
• Optimize throughput while maintaining flexibility for innovation work.
• Establish and manage hold-time standards, CIP protocols, and sanitation procedures.

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• Scale-Up & Commercialization Support
• Work with R&D to translate bench formulas into scalable pilot processes.
• Partner with R&D scientists to identify processing risks early (emulsification, stability, shear sensitivity, thermal impact).
• Support plant trials and technical transfer documentation.
• Lead process validation and parameter optimization (time/temp, shear, homogenization pressure, etc.).
• Work with TPA/QA on Pilot Retort Recipes
• Document learnings to build institutional knowledge.
• Work with Commercial team to make and send sales samples

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• Equipment & Capability Development
• Lead commissioning and qualification of new equipment in the pilot.
• Develop equipment SOPs and training materials.
• Identify capability gaps aligned with 2–3 year innovation roadmap.
• Support capital planning and ROI justification for new technologies.
• Maintain relationships with equipment vendors and service providers.

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• Safety, Compliance & Quality
• Own pilot plant safety culture and compliance standards.
• Ensure GMP compliance and food safety standards.
• Lead risk assessments and mitigation plans.
• Partner with QA to align pilot and manufacturing expectations.
• Maintain calibration, preventive maintenance, and documentation systems.

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• Team Leadership & Development
• Manage pilot plant technologists
• Develop cross-training programs to increase operational flexibility.
• Create structured onboarding and technical skill development pathways.
• Foster a proactive, solutions-oriented culture.
• Act as a visible leader who reinforces accountability and collaboration.

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• Strategic Contribution
• Align pilot plant capabilities with R&D and business strategy.
• Provide input into innovation feasibility, timelines, and risk assessments.
• Track KPIs (trial success rate, throughput, cycle time, equipment uptime, safety metrics).
• Build a continuous improvement roadmap for the facility.

Key Competencies

• Technical
• Thermal processing (HTST, UHT, retort)
• Homogenization and emulsification systems
• CIP and sanitation systems
• Food safety & GMP compliance
• Process scale-up methodology
• Equipment commissioning and troubleshooting
• Leadership
• Cross-functional collaboration
• Operational discipline
• Resource prioritization
• Coaching & technical mentorship
• Decision-making under ambiguity
• Strategic
• Commercialization mindset
• Capital planning
• Continuous improvement
• Systems thinking

Requirements

• Bachelor’s degree in Food Science, Chemical Engineering, or related field.
• 7–10+ years in food/beverage manufacturing or pilot plant operations.
• 3–5+ years of people leadership preferred.
• Experience supporting commercialization and plant trials.
• Strong knowledge of food safety standards and regulatory compliance.

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