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Process Development Engineer information

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$43.3K

$96.6K

$145K

How much do process development engineer jobs pay per year?

As of Jul 16, 2026, the average yearly pay for process development engineer in Ohio is $96,602.00, according to ZipRecruiter salary data. Most workers in this role earn between $76,500.00 and $113,100.00 per year, depending on experience, location, and employer.

What engineers make $300,000 a year?

Senior engineers in specialized fields such as petroleum, aerospace, or software engineering can earn $300,000 or more annually, especially with extensive experience, advanced skills, and leadership roles. High compensation often involves working in high-demand industries, holding managerial or executive positions, or possessing rare expertise and certifications.

What are the key skills and qualifications needed to thrive as a Process Development Engineer, and why are they important?

To thrive as a Process Development Engineer, you need a solid foundation in engineering principles, process optimization, and problem-solving, typically supported by a degree in chemical, mechanical, or industrial engineering. Familiarity with process simulation software (such as Aspen Plus or MATLAB), Six Sigma methodologies, and relevant industry certifications is often required. Strong analytical thinking, effective communication, and teamwork skills help you excel in cross-functional projects and drive continuous improvement. These skills and qualities are crucial for designing efficient processes, ensuring product quality, and supporting organizational competitiveness.

What Is a Process Development Engineer?

A process development engineer designs and plans production systems to be cost-effective, safe, and meet quality requirements for their industry. These professionals often work as part of a quality assurance team or a production management department for industrial companies, such as manufacturing or mining businesses. As a process development engineer, your job duties include reviewing the company's current production processes and designing modifications to the current system or creating new systems to increase productivity. Once you have installed or implemented the system, you make sure to test and troubleshoot it to ensure they run properly.

What are some common challenges faced by Process Development Engineers when scaling up from laboratory to production environments?

One of the main challenges Process Development Engineers encounter is ensuring that processes which work efficiently at a laboratory scale can be reliably and safely replicated in full-scale manufacturing. Differences in equipment size, process dynamics, and raw material variability can lead to unforeseen issues such as inconsistent product quality or unexpected safety hazards. Effective communication and collaboration with both R&D and production teams are essential to troubleshoot problems and optimize process parameters. Engineers often need to adapt quickly, apply problem-solving skills, and implement robust validation protocols to ensure successful scale-up.

What does a process development engineer do?

A process development engineer designs, tests, and optimizes manufacturing processes to improve efficiency, quality, and cost-effectiveness. They analyze production methods, develop new procedures, and often use tools like statistical analysis and process simulation to ensure scalable and reliable operations.

What is the difference between Process Development Engineer vs Manufacturing Engineer?

AspectProcess Development EngineerManufacturing Engineer
Primary FocusDesigning and optimizing manufacturing processes for new productsOverseeing and improving existing manufacturing processes
Work EnvironmentR&D labs, pilot plants, early-stage productionProduction floors, plant operations
Required CredentialsBachelor's or higher in engineering, experience in process designBachelor's or higher in engineering, experience in manufacturing
Industry UsagePharmaceuticals, electronics, chemicals, biotechAutomotive, consumer goods, electronics, industrial manufacturing

While both roles involve process optimization, Process Development Engineers focus on creating and refining new manufacturing processes, often in early development stages. Manufacturing Engineers typically work on maintaining and improving existing production processes to ensure efficiency and quality in ongoing operations.

What engineer makes $500,000 a year?

While most process development engineers earn between $80,000 and $150,000 annually, some senior or specialized engineers in high-demand industries or with extensive experience can earn over $200,000. Earning $500,000 typically requires executive-level roles, such as director or VP of engineering, or highly specialized positions with significant responsibilities and bonuses.

What engineers make $200,000 a year?

Senior engineers in fields such as software engineering, petroleum engineering, and aerospace engineering often earn $200,000 or more annually, especially with extensive experience, advanced skills, and in high-demand industries. Certain specialized roles, managerial positions, or engineers with advanced certifications and leadership responsibilities can also reach or exceed this salary level.
More about Process Development Engineer jobs
What are popular job titles related to Process Development Engineer jobs in Ohio? For Process Development Engineer jobs in Ohio, the most frequently searched job titles are:
What job categories do people searching Process Development Engineer jobs in Ohio look for? The top searched job categories for Process Development Engineer jobs in Ohio are:
What are popular job titles related to Process Development Engineer jobs in OH? For Process Development Engineer jobs in OH, the most frequently searched job titles are:
Process Development Engineer jobs near you
Infographic showing various Process Development Engineer job openings in Ohio as of July 2026, with employment types broken down into 1% As Needed, 81% Full Time, 16% Part Time, and 2% Contract. Highlights an 92% Physical, 2% Hybrid, and 6% Remote job distribution, with an average salary of $96,602 per year, or $46.4 per hour.
Process Development Engineer

Process Development Engineer

MRA Recruiting Services

Springboro, OH • On-site

Full-time

Medical, Dental, Vision, Life, Retirement, PTO

Re-posted 9 days ago

Job description

Process Development Engineer - Team Lead
Company: Sunstar Engineering Americas, an MRA Member
Location: Springboro, OH
Full-Time
Sunstar Engineering is a global leader in adhesives, sealants, and coatings serving automotive, construction, and electronics markets. With over 95 years of innovation, we are focused on developing the next generation of materials and technologies. Our Process R&D engineering team is focused on turning new materials into real, scalable manufacturing processes.
About the Role
We are looking for a hands-on process engineer ready to step into a leadership role.
In this role, you will lead from the floor while mentoring a small team. You will work at the intersection of R&D and manufacturing, taking new formulations and turning them into reliable, scalable processes.
You’ll lead a team of 3 engineers/technicians (4 total including you) while staying actively involved in process development and troubleshooting.
This role is ideal for someone who:
• Has early career industry experience (typically 3–8 years)
• Enjoys solving real-world processing challenges
• Wants to grow into people leadership while staying hands-on
What You’ll Do
• Develop and scale manufacturing processes for new materials
• Translate lab formulations into pilot and production-ready processes
• Lead and mentor a small process development team
• Troubleshoot and improve mixing, dispensing, and handling of complex materials
• Collaborate with R&D, manufacturing, and quality teams
• Identify opportunities to improve efficiency, cost, and robustness
What We’re Looking For
Required:
• Degree in Chemical, Mechanical, Materials Engineering, Chemistry, or related field
• 3–8 years of experience in process development, scale-up, or manufacturing support
• Experience working with complex materials (e.g., filled systems, polymers, pastes, slurries)
• Strong problem-solving and data-driven mindset
• Interest in mentoring and guiding others
• Ability to communicate across technical and operations teams
Preferred:
• Experience with adhesives, sealants, coatings, or similar materials
• Familiarity with pilot-scale equipment or plant trials
• Experience with DOE tools (JMP, Minitab), machine learning, or continuous improvement methods
Benefits
What’s in it for you?
  • 401(k) matching
  • Dental insurance
  • Health insurance
  • Life insurance
  • Paid time off
  • Retirement plan
  • Vision insurance

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