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Process Development Engineer Jobs in Chicago, IL

Hollister Incorporated

Lead R&D Engineer

Libertyville, IL · On-site

$99K - $131K/yr

The Lead R&D Engineer will lead or participate in new product development project teams to drive ... Demonstrate advanced proficiency in product development processes such as Stage Gate, design ...

Hollister Incorporated

Lead R&D Engineer

Libertyville, IL · Hybrid

$99K - $131K/yr

The Lead R&D Engineer will lead or participate in new product development project teams to drive ... Demonstrate advanced proficiency in product development processes such as Stage Gate, design ...

Hollister Incorporated

Lead R&D Engineer

Libertyville, IL · Hybrid

$99K - $131K/yr

The Lead R&D Engineer will lead or participate in new product development project teams to drive ... Demonstrate advanced proficiency in product development processes such as Stage Gate, design ...

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All JobsProcess Development Engineer JobsProcess Development Engineer Jobs in Chicago, IL

Process Development Engineer information

See Chicago, IL salary details

$46.9K

$104.7K

$157.1K

How much do process development engineer jobs pay per year?

As of Jul 16, 2026, the average yearly pay for process development engineer in Chicago, IL is $104,675.00, according to ZipRecruiter salary data. Most workers in this role earn between $82,900.00 and $122,600.00 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
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What job categories do people searching Process Development Engineer jobs in Chicago, IL look for? The top searched job categories for Process Development Engineer jobs in Chicago, IL are:
Process Development Engineer jobs near you
ILUS - Product Development Engineer

ILUS - Product Development Engineer

Daifuku

Hobart, IN

Other

Re-posted 24 days ago

Daifuku rating

7.4

Company rating: 7.4 out of 10

Based on 33 frontline employees who took The Breakroom Quiz

249th of 430 rated machine equipment manufacturers

Job description

Overview

Under direction, develops new products, models, and mechanisms for conveyor systems and applications. Works on typically small-scale, less complex projects with support from more senior engineers.

Responsibilities
  • Participates in conceiving, designing, developing, engineering, prototyping, testing, and revising typically small-scale, less complex, new fabricated products for conveyor systems and applications
  • Supports the process for engineering calculations to ensure a robust design, including horsepower, stress, torque, deflection, torsion, overhung load, sortation rate, cycle rate, air consumption, and amperage draw
  • Participates in working with other teams to troubleshoot and resolve development and design issues
  • Ensures that new products are safe, reliable, and easy to maintain
  • Recommends appropriate and cost-effective purchased products
  • Helps to analyze data to identify trends in usage, cost, performance, and reliability
  • Participates in developing and executing test plans for concepts and prototypes to establish operational parameters
  • Uses modeling and simulation tools to prove or disprove designs
  • Partners with the Design team, Manufacturing, Quality Control, Purchasing and Administration
  • Travels up to 20%
Qualifications

Education and Experience Requirements 

  • Bachelor's Degree in Mechanical Engineering or Product Development or equivalent experience
  • Minimum of internship or 1 year of experience in the material handling industry preferred
  • Introductory experience in conveyor systems with carton handling or pallet handling
  • Introductory experience with Motor Drive Roller (MDR), Sortation Technologies, installation, project management, electrical, or Solidworks Enterprise PDM administration highly desirable

Knowledge, Skills and Abilities Requirements

  • Knowledge of design and development of conveyor-related products
  • Experience with AutoCAD, Solidworks, Solidworks Enterprise PDM, Microsoft Office and simulation modules
  • Ability to adapt to changing priorities in a fast-paced results-oriented environment
  • Organizational skills to meet project plans and deadlines
  • Excellent written and verbal communication and interpersonal skills
  • Strategic and creative thinking and problem-solving skills
  • Team-oriented and collaborative
  • Ability to learn new skills and technologies

EOE Minorities/Women/Disabled/Veterans

Federal Contractor

Employment Type: OTHER

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