The Senior Reliability Engineer – Valves & Seals leads strategic initiatives to maximize the performance, reliability, and lifecycle efficiency of valve and seal systems in sanitary and utility processes. This senior-level role plays a critical part in ensuring hygienic design integrity, minimizing unplanned downtime, and enhancing preventive and predictive maintenance (PM/PdM) programs. The engineer serves as a technical expert on valve and sealing technologies, guiding cross-functional reliability efforts across multiple facilities, and mentoring junior team members.
Own and drive the reliability roadmap for valves and sealing systems across product, CIP/SIP, utility, and packaging operations.
Lead and facilitate failure mode and effects analysis (FMEA), root cause analyses (RCA), and reliability-centered maintenance (RCM) programs.
Develop asset health monitoring strategies including condition-based maintenance using pressure, temperature, vibration, and acoustic sensors.
Analyze valve and seal performance trends using CMMS and downtime data to identify chronic issues, reliability gaps, and redesign opportunities.
Establish and track KPIs (e.g., MTBF, MTTF, seal life span) to evaluate reliability performance and progress.
Champion continuous improvement initiatives to reduce seal failure rates, CIP failures, and cross-contamination risks.
Specify valve, actuator, and seal materials based on process conditions (e.g., temperature, pressure, cleaning chemicals).
Develop and enforce standard engineering practices, installation protocols, and torque/sealing specifications across sites.
Collaborate with OEMs, integrators, and procurement to qualify, select, and standardize high-reliability valve/seal components.
Ensure all reliability practices related to valve and seal systems support compliance with FDA, FSMA, USDA, 3-A, and EHEDG standards.
Support validation, audit readiness, and documentation of critical valve/seal systems in collaboration with QA and Sanitation.
Serve as a technical SME for valve and seal reliability in new equipment designs, retrofits, and capital expansion projects.
Partner with Maintenance, Operations, QA, and Engineering teams to build a reliability-focused plant culture.
Mentor junior reliability engineers and technicians in root cause techniques, hygienic standards, and reliability tools.
Valve and seal lifecycle optimization in food and CIP/SIP systems
Advanced reliability analytics and predictive maintenance
Cross-functional project and failure prevention leadership
Compliance with sanitary design and food safety standards
Supplier standardization and technical negotiations
Knowledge sharing and team mentoring
Bachelor’s degree in Mechanical, Industrial, or Process Engineering required
Master’s degree or PE license preferred
Certified Maintenance & Reliability Professional (CMRP)
Six Sigma Black/Green Belt
PCQI, HACCP, or 3-A Sanitary Design experience is a plus
8+ years of experience in maintenance or reliability engineering, with a strong focus on valves, seals, and rotating equipment
Significant experience in food, beverage, dairy, pharmaceutical, or other regulated process manufacturing environments
Demonstrated success implementing RCM, PdM technologies, and data-driven failure prevention strategies
Expertise in seal wear patterns, hygienic valve design, elastomer compatibility, and actuator behavior
Proficient with CMMS systems (SAP PM, Maximo), RCA tools (Apollo, TapRooT), and reliability software (RCM++, Weibull)
Strong leadership, influencing, and team-building capabilities
Excellent communication, documentation, and cross-departmental collaboration skills