Sr. Chemical Engineer, Explosives Processing

Sr. Chemical Engineer, Explosives Processing

SIG SAUER, Inc. is a leading provider and manufacturer of firearms, electro-optics, ammunition, airguns, suppressors, remote controlled weapons stations, and training. For over 250 years SIG SAUER, Inc. has evolved, and thrived, by blending American ingenuity, German engineering, and Swiss precision. Today, SIG SAUER is synonymous with industry-leading quality and innovation which has made it the brand of choice amongst the U.S. Military, the global defense community, law enforcement, competitive shooters, hunters, and responsible citizens. Additionally, SIG SAUER is the premier provider of elite firearms instruction and tactical training at the SIG SAUER Academy. Headquartered in Newington, New Hampshire, SIG SAUER has over 3,400 employees across sixteen U.S. locations in three states, and four additional global facilities. SIG SAUER is certified a Great Place to Work™. For more information about the company and product line visit: www.sigsauer.com

Position Summary: The Sr. Chemical Engineer, Explosives Processing, will use their engineering talent to design, develop, effectively implement, and constantly improve production processes related to energetic materials contributing to the manufacture of elite, world-class ammunition for the consumer, law enforcement, and military markets. This role will focus on, but not limited to, ammunition primer manufacturing. Due to the nature of high energetic batch processing, all responsibilities of this role will have close collaboration and interaction with SIG Research & Development, retained energetic consultants, Energetic Safety Committee, EHS, Operations, and additional key stakeholders. This position requires a senior level Engineer with previous experience in establishing and technically supporting the production of energetic batch processing.

FLSA: Exempt

Job Duties and Responsibilities:

• Design, develop, optimize, monitor, and maintain chemical manufacturing processes for explosives and energetic materials, including formulation, mixing, blending, granulation, pressing, extrusion, drying, packaging, desensitization, and wastewater pretreatment.
• Conduct process hazard analyses (PHA), HAZOP studies, and risk assessments specific to explosive sensitivities such as friction, impact, electrostatic discharge, and thermal stability and implement controls to minimize employees. 
• Establish and maintain Process Safety Management (PSM) programs per OSHA 29 CFR 1910.119, ATF Federal Explosives Regulations (27 CFR 555), DoD 4145.26-M, DOT hazardous materials rules, and EPA requirements including Process Safety

Information (PSI), operating procedures, mechanical integrity, and management of change (MOC). 

• Develop, review, and update standard operating procedures (SOPs), batch records, and safety protocols for handling dangerous chemicals and energetic materials.
• Create training programs and deliver hands-on safety instruction to operators and contractors. 
• Design and specify process equipment and facility layout with remote operation, blast-resistant construction, quantity-distance separation, and automated controls to ensure safe, efficient production while meeting environmental and regulatory standards.
• Create SIG SAUER machine specifications, system requirement documents (SRD), and Statements of Work (SOW) where applicable. 
• Monitor production performance through data collection, statistical process control, yield tracking, and real-time analysis; troubleshoot deviations, equipment failures, or quality issues and implement corrective and preventive actions. 
• Lead or support commissioning, qualification, and validation of new or modified processes and equipment; perform pre-startup safety reviews (PSSR) and participate in change management reviews.
• Investigate incidents or near-misses, perform root-cause analysis, and develop corrective action plans.
• Participate in regulatory audits and inspections by OSHA, ATF, EPA, or DoD.
• Collaborate with cross-functional teams such as Production, Quality, Maintenance, Research & Development, and EHS to drive continuous improvement in safety, efficiency, cost, and sustainability while ensuring compliance with all applicable regulations.
• Estimate production costs, prepare technical reports, and support budgeting for process upgrades or capital projects.
• Assist and consult on non-PSM activities such as wash solution titrations and chemical compatibilities of solutions and materials

Education/Experience & Skills:

• Bachelor or Science degree in Chemical Engineering or related Engineering or Science discipline with 7-10 years minimum relevant work experience; Master’s degree is preferred.