Phlow · 1 month ago
API Manufacturing Process Safety Engineer
Petersburg, VA
Full-time
Onsite
Mid, Senior LevelPhlow Corp is seeking an API Manufacturing Process Safety Engineer to own and build the API Manufacturing Process Safety program from the ground up for small-molecule API manufacturing at the Petersburg, VA campus. This position is directly responsible for the process safety activities associated with technology transfer, process design, and GMP startup, ensuring safe, compliant, and reliable operations.
ChemicalHealth CareManufacturingPharmaceutical
Responsibilities
Build, implement, and continually improve the API Process Safety program in alignment with OSHA PSM, EPA requirements, and Phlow procedures
Own and lead PFMEAs, PHAs, and PSSRs for new and existing API processes; translate outcomes into practical engineered and administrative controls for GMP operations
Identify and control hazards typical to API operations (e.g., exotherms, overpressure, vacuum collapse, flammable/toxic releases, static, dust deflagration) and ensure safeguards are in place and effective
Coordinate thermal hazard characterization (e.g., DSC/ARC/RC1) and ensure data are integrated into equipment design, operating limits, automation strategies, interlocks, and procedures
Develop and support relief and vent strategies (PSVs/rupture discs, vent sizing, scrubbers/containment) and contribute to LOPA/SIL evaluations and verification of assumptions
Own the process safety portion of the MOC process by evaluating risk impacts, defining required safeguards, and confirming PSI updates, training, and startup readiness
Define mechanical integrity expectations for critical protective systems and instrumented functions; work closely with Maintenance and Engineering to prioritize and validate testing
Lead or participate in incident and near-miss investigations related to process and equipment; perform root cause analysis and track corrective/preventive actions to closure
Develop and deliver training and coaching for employees and contractors on process safety and life safety requirements related to API manufacturing
Collaborate closely with Tech Transfer, GMP Manufacturing GMP Manufacturing Operations, Process Engineering, Quality & Regulatory, Facility Security, and local emergency responders to support drills, pre-incident planning, and safe execution of campaigns
Qualification
Required
Bachelor's degree in Chemical Engineering or a closely related engineering discipline
Working knowledge of OSHA/EPA regulations and core PSM elements (PHA/HAZOP, LOPA/SIL concepts, MOC, PSSR, incident investigation)
Proficiency with process safety tools and documentation (PSI, risk assessments, action tracking)
Strong analytical and problem-solving skills with the ability to collaborate in cross-functional teams
Ability to work in a fast-paced environment with regular field presence in manufacturing areas
Solid technical proficiency in process safety methods and engineering fundamentals
Ability to perform structured risk assessments and recommend practical mitigation strategies
Effective communication and interpersonal skills at all organizational levels
Strong organizational skills and the ability to manage multiple tasks and priorities
Continuous improvement mindset and attention to detail
Preferred
Experience in process safety, chemical engineering, or EHS in manufacturing (pharma/API or chemical processing preferred)
Practical experience with exothermic/reactive chemistry, overpressure protection, or cryogenic/flammable systems
Company
Phlow
Phlow supplies affordable, quality, essential medicines through U.S.-based advanced manufacturing processes.
Founded in 2020
51-200 employees
H1B Sponsorship
Phlow has a track record of offering H1B sponsorships. Please note that this does not
guarantee sponsorship for this specific role. Below presents additional info for your
reference. (Data Powered by US Department of Labor)
Distribution of Different Job Fields Receiving Sponsorship
Represents job field similar to this job
Trends of Total Sponsorships
2024 (1)
2023 (1)
Funding
Current Stage
Growth StageTotal Funding
$117.2MKey Investors
Align Private Capital
2025-07-22Series C· $37M
2023-04-05Series B· $36M
2022-09-02Series Unknown· $24.2M
Leadership Team
Eric Edwards
Co-Founder and CEO
Recent News
The Virginian-Pilot
2025-10-24
2025-10-21
Company data provided by crunchbase