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Process Engineer Jobs in Saint Charles, IL (NOW HIRING)

Hoffer Plastics

Process Engineer

South Elgin, IL · On-site

$85K - $115K/yr

Hoffer Plastics is hiring for " Process Engineer ", " 1st shift ". Starting Pay $85k - $115K (based on experience) ESSENTIAL RESPONSIBILITIES: * NEW TOOL REVIEW Participate in the review of new molds ...

Clayens US LLC

Process Engineer

Crystal Lake, IL · On-site

Monitor performance of process parameters that produce non-conforming products, low yields, or product quality issues. Interfaces with Quality and Engineering Departments to resolve manufacturing ...

Zachry Group

Engineer II Process

Downers Grove, IL · On-site

$84K - $119K/yr

The Process Engineer II will be responsible for routine process engineering and design tasks for assigned projects based on specific and detailed instructions received from the assigned supervisor.

CTS Corporation

Process Engineer

Lisle, IL · On-site

$115K/yr

Position Summary The Process Engineer reports directly to the Plant Manager and supports the Ceramic business. In this role, the Process Engineer makes technical decisions related to ceramic ...

Vantage Specialty Chemicals

Process Engineer

Chicago, IL · On-site

$88K - $132K/yr

Process Engineer Position Summary Support all chemical processing units and operations by leveraging chemical engineering and technical expertise to drive continuous improvement initiatives, process ...

Ionbond

Process Engineer

West Chicago, IL · On-site

Ionbond is looking for a dynamic Process Engineer to collaborate closely with our Plant Manager and local team, driving the development of the Ionbond™ family of coatings and services. If you have ...

Combined Metals

Process Engineer

Elgin, IL · On-site

Utilize statistical methods to monitor processes and guide process improvements. Education: * Bachelor's degree in Metallurgy, Metallurgical Engineering, Material Engineering/Science, or a closely ...

Combined Metals of Chicago

Process Engineer

Elgin, IL · On-site

$70K - $80K/hr

Utilize statistical methods to monitor processes and guide process improvements. Education: * Bachelor's degree in Metallurgy, Metallurgical Engineering, Material Engineering/Science, or a closely ...

Amp Americas

Project & Process Engineer

Chicago, IL · On-site

Position Summary The Project & Process Engineer combines process engineering, continuous improvement, and project execution. The long-term focus of the position will be to identify, develop, and ...

Amp Americas

Project & Process Engineer

Chicago, IL · On-site

Position Summary The Project & Process Engineer combines process engineering, continuous improvement, and project execution. The long-term focus of the position will be to identify, develop, and ...

Burgess Norton Mfg Co

Senior Process Engineer

Geneva, IL · On-site

$123K - $157K/yr

Manage Manufacturing / Process Engineering projects for Cold Form & Finishing facilities and support global grinding processes for parts production (including manufacturing location decisions ...

Ecolab

Principal Process Engineer

Chicago, IL · On-site

$101K - $152K/yr

Ecolab is looking for an experienced Principal Process Engineer with a strong background in industrial manufacturing at our Clearing, IL manufacturing facility. Clearing is the flagship manufacturing ...

Zachry Group

Sr Engineer Process

Downers Grove, IL

$148K - $211K/yr

Zachry Group is currently accepting applications for a Senior Process Engineer in our Downers Grove Engineering Design Center . Successful candidate will be responsible for leading a team supporting ...

Burgess Norton Mfg Co

Senior Process Engineer

Geneva, IL · On-site

$123K - $157K/yr

Manage Manufacturing / Process Engineering projects for Cold Form & Finishing facilities and support global grinding processes for parts production (including manufacturing location decisions ...

Plexus Corp.

Process Engineer

Buffalo Grove, IL · On-site

$70K - $105K/yr

The Process Engineer is responsible for providing technical expertise throughout the manufacturing process. This role involves offering guidance on best practices and equipment, optimizing production ...

Ecolab

Principal Process Engineer

Chicago, IL

$101K - $152K/yr

Ecolab is looking for an experienced Principal Process Engineer with a strong background in industrial manufacturing at our Clearing, IL manufacturing facility. Clearing is the flagship manufacturing ...

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Showing results 21-40

All JobsProcess Engineer JobsProcess Engineer Jobs in Saint Charles, IL

Process Engineer information

See Saint Charles, IL salary details

$48.4K

$90K

$139.4K

How much do process engineer jobs pay per year?

As of Sep 2, 2026, the average yearly pay for process engineer in Saint Charles, IL is $90,009.00, according to ZipRecruiter salary data. Most workers in this role earn between $72,900.00 and $100,800.00 per year, depending on experience, location, and employer.

What is a process engineer?

Process Engineers are professionals who design, implement, and optimize industrial processes to improve efficiency, quality, and safety in manufacturing or production environments. They analyze workflows, troubleshoot process issues, and develop solutions to enhance productivity and reduce costs. Process Engineers often work in industries such as chemicals, pharmaceuticals, food and beverage, and energy, ensuring processes are compliant with environmental and safety regulations. Their work is vital for maintaining smooth operations and achieving organizational goals.

What are the key skills and qualifications needed to thrive as a process engineer, and why are they important?

To thrive as a Process Engineer, you need a solid background in chemical, mechanical, or industrial engineering, often supported by a relevant bachelor's degree and understanding of process optimization principles. Familiarity with process simulation software (such as Aspen Plus or AutoCAD), Six Sigma methodologies, and quality management systems is typically required. Strong analytical thinking, problem-solving abilities, and effective communication skills set candidates apart in this role. These skills and qualifications are essential to improve efficiency, ensure safety, and drive continuous improvement in industrial and manufacturing processes.

What are some common challenges process engineers face when implementing process improvements, and how can they overcome them?

Process Engineers often encounter challenges such as resistance to change from team members, integrating new technologies with existing systems, and ensuring process changes meet regulatory standards. Overcoming these obstacles typically involves clear communication, involving stakeholders early in the process, thorough documentation, and piloting changes before full-scale implementation. Building strong cross-functional relationships and continuously gathering feedback also help ensure that improvements are effective and sustainable.

What is the difference between Process Engineer vs Manufacturing Engineer?

AspectProcess EngineerManufacturing Engineer
CredentialsBachelor's in Engineering, certifications like Six SigmaBachelor's in Engineering, certifications like Lean Manufacturing
Work EnvironmentDesigning and optimizing processes, R&D settingsOverseeing production lines, factory floors
Industry UsageManufacturing, chemical, aerospaceAutomotive, electronics, consumer goods

Process Engineers focus on designing and improving manufacturing processes, often working in R&D or engineering departments. Manufacturing Engineers concentrate on implementing and managing production on the factory floor. Both roles require similar technical skills and certifications but differ mainly in their scope and work environment.

What jobs can a process engineer do?

A process engineer designs, develops, and optimizes manufacturing processes to improve efficiency, quality, and safety. They work in industries such as chemical, pharmaceutical, food, and automotive, often using tools like process simulation software and requiring knowledge of quality standards and safety regulations.
More about Process Engineer jobs

What are the most commonly searched types of Process Engineer jobs in Saint Charles, IL?

The most popular types of Process Engineer jobs in Saint Charles, IL are:

What are popular job titles related to Process Engineer jobs in Saint Charles, IL?

For Process Engineer jobs in Saint Charles, IL, the most frequently searched job titles are:

What job categories do people searching Process Engineer jobs in Saint Charles, IL look for?

The top searched job categories for Process Engineer jobs in Saint Charles, IL are:

What cities near Saint Charles, IL are hiring for Process Engineer jobs?

Cities near Saint Charles, IL with the most Process Engineer job openings:

Process Engineer jobs near you
Infographic showing various Process Engineer job openings in Saint Charles, IL as of August 2026, with employment types broken down into 1% As Needed, 76% Full Time, 15% Part Time, 5% Contract, and 3% Nights. Highlights an 91% Physical, 3% Hybrid, and 6% Remote job distribution, with an average salary of $90,009 per year, or $43.3 per hour.

Process Engineer

Hoffer Plastics

South Elgin, IL • On-site

$85K - $115K/yr

Full-time

Medical, Dental, Vision, Life, PTO

Posted 6 days ago

Job description

Want to be part of something special? We're Filling Important Jobs!
Join an industry leader and innovator looking for people who want to make a difference.
Hoffer Plastics is hiring for " Process Engineer", "1st shift".
Starting Pay $85k - $115K (based on experience)
ESSENTIAL RESPONSIBILITIES:
  1. NEW TOOL REVIEW

Participate in the review of new molds, transferred molds, engineering changes, and new product launches to ensure the tooling and manufacturing process are designed for successful production.
  • Participate in new product and tooling review meetings throughout the development process.
  • Review part and mold designs from an injection molding and Design for Manufacturing (DFM) perspective.
  • Identify potential processing, tooling, material, quality, automation, and production risks before the mold reaches production.
  • Review proposed gate locations, runner systems, hot runner systems, cooling requirements, venting, ejection, cavity layout, and other mold features that can affect process capability.
  • Review available mold-flow or simulation information and provide processing input when appropriate.
  • Evaluate projected cavity pressures, clamp-tonnage requirements, shot-size requirements, recovery requirements, expected cycle time, and other machine requirements.
  • Determine whether the proposed mold is compatible with available injection molding machines and identify required auxiliary equipment.
  • Review mold water requirements and verify that adequate water circuits, flow, pressure, and temperature control are available.
  • Participate in tool trials and mold samplings as required and document processing or tooling concerns for the project team.
  • Work with Engineering, Tooling, Quality, and Manufacturing to resolve identified concerns before production launch whenever possible.
  • Support domestic and international tool shops as required during mold build, sampling, and debugging.
  1. PROCESS DEVELOPMENT

Develop a robust, repeatable, and documented injection molding process that can be successfully transferred to normal production.
  • Coordinate and participate in mold samplings and process-development activities using scientific and decoupled molding principles.
  • Establish a repeatable molding process based on actual process data rather than machine settings alone.
  • Perform appropriate process-development studies to establish the molding window and understand the response of the process to normal manufacturing variation.
  • Evaluate fill speed, transfer position, cavity balance, injection pressure, hold pressure, hold time, cooling time, melt temperature, mold temperature, clamp tonnage, recovery, and other critical process variables.
  • Verify that the process operates within the capabilities of the selected injection molding machine and establish upper and lower limits for critical variables where appropriate.
  • Verify that the developed process produces acceptable product under normal production conditions and identify critical process parameters and potential failure points.
  • Work with Quality to verify dimensional and functional product requirements during process development.
  • Develop and maintain clear process documentation covering mold setup, machine requirements, process settings and limits, material and drying requirements, auxiliary equipment, water, automation, and special instructions.
  • Assist with the transition of newly developed processes from Engineering into Manufacturing and support the initial production startup.
  • Verify that the developed process can be duplicated by plant personnel and train appropriate personnel on new processes and special processing requirements.
  1. PRODUCTION SUPPORT

Provide technical support to Manufacturing when production problems cannot be resolved through normal plant troubleshooting activities.
  • Support manufacturing personnel with difficult, chronic, or recurring injection molding problems.
  • Troubleshoot issues involving the process, machine, mold, material, hot runner system, temperature-control equipment, dryers, material handling, robots, automation, and other auxiliary equipment.
  • Use a structured troubleshooting approach to identify the actual cause of production problems and separate process-related issues from tooling, equipment, material, and quality issues.
  • Review actual process data and machine performance before recommending changes.
  • Ensure process changes remain within the established process window whenever possible and avoid using processing changes to compensate for tooling or equipment conditions that should be corrected.
  • Work with Plant Managers, Process Technicians, Maintenance, Tooling, Engineering, and Quality to resolve production issues.
  • Assist plants with difficult mold startups, process transfers, and recurring production problems.
  • Verify corrective actions are effective, document significant process changes, and update process documentation when approved permanent changes are made.
  • Provide technical coaching and training to processing personnel as needed.
  1. SCRAP REDUCTION AND CONTINUOUS IMPROVEMENT

Actively identify and pursue opportunities to reduce scrap, improve productivity, improve process capability, and eliminate recurring manufacturing problems.
  • Review plant scrap and defect data to identify the largest processing-related opportunities and prioritize improvement projects based on measurable business impact.
  • Work with Manufacturing and Quality to identify the true root causes of recurring defects using data-driven problem-solving rather than trial-and-error processing.
  • Evaluate process capability and identify processes operating near or outside their established processing window.
  • Identify molds or processes that require redevelopment or optimization and perform structured studies to determine the relationship between process variables and product quality.
  • Lead or participate in corrective-action activities involving molding processes.
  • Develop corrective actions that address root cause rather than simply adjusting machine settings to temporarily eliminate symptoms.
  • Identify opportunities to reduce scrap, startup scrap, downtime, cycle time, material usage, colorant usage, energy consumption, and unplanned process adjustments.
  • Work with Tooling and Maintenance when process data indicates mechanical or tooling conditions are contributing to scrap.
  • Verify improvements through measurable before-and-after results and standardize successful improvements across similar molds, machines, or facilities when appropriate.
  • Maintain documentation of significant improvements and lessons learned.
  1. TECHNOLOGY ADVANCEMENT AND PROCESS DEVELOPMENT STRATEGY

Continuously advance the company's injection molding knowledge, process-development methods, and technical capabilities so new-tool qualification and launch strategies improve as technology and industry knowledge evolve.
  • Stay current with advancements in injection molding technology, scientific molding, process-development strategies, mold technology, machine controls, process monitoring, automation, materials, and auxiliary equipment.
  • Continuously evaluate industry best practices and determine whether they can improve the company's process-development methodology and new-tool launch process.
  • Research new process-development studies and techniques that can provide a better understanding of mold, machine, material, and process capability before a tool is released to production.
  • Identify opportunities to expand or improve standard process-development tests based on lessons learned from tool launches, production issues, scrap investigations, and industry advancements.
  • Develop, test, and validate new process-development studies before incorporating them into the company's standard tool-launch process.
  • Regularly review existing process-development tests to determine whether additional data, calculations, acceptance criteria, or testing methods could improve their effectiveness.
  • Use mold sampling to develop a deeper understanding of mold capability, machine capability, material behavior, process sensitivity, cavity-to-cavity variation, cooling performance, pressure requirements, flow characteristics, process repeatability, process-window size, and potential production risks.
  • Look beyond whether a mold can simply produce an acceptable part and determine how robust the overall molding system will be under normal production variation.
  • Evaluate new methods for testing machine capability and determining whether a molding machine is appropriate for a particular mold and process.

PHYSICAL REQUIREMENTS: Incumbent will:
  • usually stand/walk most of the shift.
  • frequently bend at waist, twist, kneel/crouch, climb ladders, and climb up on machinery with proper fall protection.
  • occasionally push, pull, and lift up to 75 lbs. or more.
  • occasionally lift above waist and/or shoulder up to 75 lbs. and over.
  • sometimes perform hand/wrist/finger movements and foot movements for pedal controls on forklift.
  • occasionally perform keyboarding and squeezing movements.
  • frequently be exposed to odors, dust, oil/grease, heat, noise, and operating machinery.

QUALIFICATIONS:
  • Five or more years of direct injection molding processing experience or equivalent applicable experience.
  • Strong understanding of scientific molding and decoupled molding principles.
  • Demonstrated ability to develop and troubleshoot injection molding processes.
  • Strong mechanical aptitude and ability to interpret molding-machine and process data.
  • Ability to systematically troubleshoot mold, machine, material, process, and auxiliary-equipment problems.
  • Strong analytical, problem-solving, verbal, written, and technical documentation skills.
  • Ability to work effectively with Engineering, Manufacturing, Quality, Tooling, Maintenance, suppliers, and management.
  • Computer proficient and able to use data-analysis and process-documentation tools.
  • Ability to travel to manufacturing facilities, suppliers, and tool shops as required.
  • Associate degree in Engineering, Engineering Technology, Plastics, Manufacturing, Mechanical, or related technical field preferred; Bachelor's degree in Engineering or related discipline preferred. Equivalent direct injection molding experience may be considered in place of formal education.
  • RJG, AIM, Paulson, or equivalent advanced injection molding training strongly preferred.

Benefits:
  • Blue Cross Blue Shield Medical, Dental and VSP Vision Insurance
  • Hoffer Plastics matches .50 per $1.00 dollar contributed each payroll period up to 6% plus a Safe Harbor contribution of an amount equal to 3% of employee's annual eligible earnings
  • Paid Life Insurance in the amount of 1.5 times basic annual salary
  • Short term and Long-term Disability
  • 2 Weeks Paid Vacation and up to 5 Days of Illinois Paid Leave.
  • 9 Paid Holidays
  • Reimbursements (Tuition, Prescription Safety Glasses, Steel Toe Shoe, and Fitness)

Join an established, growing third generation U.S. company that goes "All In" for people, plastics and purpose.
Hoffer Plastics Corporation: There's a part of us in Every Piece.
Hoffer Plastics is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, race, color, religion, sex, sexual orientation, gender identity, national origin, disability or veteran status.

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