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Senior Process Development Engineer Jobs in Colorado

Electra

Staff Process Development Engineer

Boulder, CO · On-site

This role will serve as a senior technical resource within process engineering, driving complex development efforts, shaping technical approaches, and partnering across engineering teams to support ...

RMSL

Senior Process Engineer

Littleton, CO · On-site

$105K - $135K/yr

SENIOR PROCESS ENGINEER | Plant Design Rocky Mountain Scientific Laboratory Department: Advanced ... Development of process instrumentation and control in coordination with automation engineers

New Generation Wellness

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Nutraceutical Manufacturing Senior Process Engineer

Colorado Springs, CO · On-site

$110K - $130K/yr

The Senior Process Engineer is responsible for designing, optimizing, and scaling manufacturing ... This role leads process development and validation from pilot through commercial scale, drives ...

Relocation assistance

Voyager Technologies, Inc.

Senior Process Engineer

Pueblo, CO · On-site

$102K - $132K/yr

The Senior Process Engineer will be located onsite in Pueblo, CO and reports to the Manufacturing ... Own the end-to-end process lifecycle - spanning early development and feasibility through scale-up ...

Three Point Solutions

Sr Process Engineer

Boulder, CO · On-site

$45 - $50/hr

Job Title: Sr Process Engineer Client: Medical Device Manufacturing Company Duration: 2 Years ... Collaborate with R&D, Quality, and Manufacturing teams to improve product quality and production ...

DISA Technologies

Senior Process Engineer

Westminster, CO · On-site

$105K - $135K/yr

The Senior Process Engineer will collaborate closely with internal teams, consultants, and strategic partners to support R&D, pilot campaigns, and field deployments. The successful candidate will ...

Three Point Solutions

Sr Process Engineer

Boulder, CO · On-site

$48 - $50/hr

Job Title: Sr Process Engineer Client: Medical Device Manufacturing Company Location: Boulder, CO ... Work with R&D, Quality, and Manufacturing * Lead process validation and optimization * Mentor ...

DISA Technologies

Senior Process Engineer

Westminster, CO

$105K - $135K/yr

The Senior Process Engineer will collaborate closely with internal teams, consultants, and strategic partners to support R&D, pilot campaigns, and field deployments. The successful candidate will ...

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Senior Process Development Engineer information

See Colorado salary details

$78.9K

$127.4K

$179.3K

How much do senior process development engineer jobs pay per year?

As of Aug 31, 2026, the average yearly pay for senior process development engineer in Colorado is $127,356.00, according to ZipRecruiter salary data. Most workers in this role earn between $109,400.00 and $141,400.00 per year, depending on experience, location, and employer.

What does a senior process development engineer do?

A Senior Process Development Engineer is responsible for designing, developing, and optimizing manufacturing processes to improve efficiency, quality, and cost-effectiveness. They often lead teams in scaling up processes from the laboratory to full production, troubleshoot technical issues, and implement new technologies or methods. Additionally, they collaborate with cross-functional teams, including R&D, quality assurance, and production, to ensure processes meet regulatory and safety standards. Their expertise helps companies maintain competitive advantages and meet production goals.

What are the key skills and qualifications needed to thrive as a senior process development engineer?

To thrive as a Senior Process Development Engineer, you need a strong background in chemical or mechanical engineering, process optimization, and project management, typically supported by a relevant engineering degree. Familiarity with CAD software, process simulation tools (such as Aspen Plus or MATLAB), and Six Sigma or Lean Manufacturing certifications is often required. Excellent problem-solving, leadership, and communication skills help you coordinate cross-functional teams and drive continuous improvement. These skills are crucial for developing efficient, scalable processes that meet quality standards and business goals.

What are some common challenges a senior process development engineer may face when scaling up a new process from the lab to full production?

Senior Process Development Engineers often encounter challenges such as maintaining product quality and consistency when transitioning from small-scale laboratory experiments to large-scale manufacturing. This process typically involves troubleshooting equipment limitations, optimizing process parameters, and ensuring compliance with safety and regulatory standards. Effective collaboration with cross-functional teams, such as R&D, manufacturing, and quality assurance, is crucial to address these challenges and achieve a smooth scale-up. Adaptability and problem-solving skills are essential to navigate unexpected issues that may arise during this transition.

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

AspectSenior Process Development EngineerProcess Engineer
CredentialsBachelor's or Master's in Chemical, Mechanical, or Industrial Engineering; experience in process developmentBachelor's degree in Engineering or related field; entry to mid-level experience
Work EnvironmentResearch and development labs, manufacturing facilities, cross-functional teamsManufacturing plants, production lines, process optimization teams
Industry UsagePharmaceuticals, chemicals, biotech, manufacturingManufacturing, chemical processing, consumer goods

The main difference is that Senior Process Development Engineers focus on developing and optimizing new processes, often in R&D settings, while Process Engineers typically oversee existing manufacturing processes to improve efficiency and quality. Senior roles involve more strategic planning and innovation, whereas Process Engineers focus on day-to-day process operations.

What are popular job titles related to Senior Process Development Engineer jobs in Colorado?

For Senior Process Development Engineer jobs in Colorado, the most frequently searched job titles are:

What job categories do people searching Senior Process Development Engineer jobs in Colorado look for?

The top searched job categories for Senior Process Development Engineer jobs in Colorado are:

What cities in Colorado are hiring for Senior Process Development Engineer jobs?

Cities in Colorado with the most Senior Process Development Engineer job openings:

Senior Process Development Engineer jobs near you
Infographic showing various Senior Process Development Engineer job openings in Colorado as of August 2026, with employment types broken down into 1% As Needed, 78% Full Time, 19% Part Time, and 2% Contract. Highlights an 91% Physical, 3% Hybrid, and 6% Remote job distribution, with an average salary of $127,356 per year, or $61.2 per hour.

Sr. Process Development Engineer - Pyrolysis Test

Charm Industrial

Fort Lupton, CO

$114K - $147K/yr

Full-time

Medical, Dental, Vision, Retirement, PTO

Re-posted 9 days ago

Job description

About Charm
 
Our mission is to return the atmosphere to 280 ppm CO. We convert excess inedible biomass into carbon-rich bio-oil and inject it into underground storage for permanent carbon removal. At scale, we can use bio-oil to make fossil-free iron.
 
Our carbon removal efforts began in 2020 with initial purchases from customers like Stripe, Shopify, and Microsoft. Since then, we've scaled to thousands of tons of carbon removal, grown to over a hundred employees, and established three locations in San Francisco, Colorado, and Louisiana.
 
We're expanding our team of ambitious, creative, and hands-on problem solvers. We value psychological safety, collaboration, and continuous learning. We take calculated risks and treat mistakes as opportunities to improve. If you're excited about tackling big challenges, we encourage you to explore our company values.
 
Come help us reverse climate change. Gigatons or bust!

About the Role 

We're looking for a Senior Process Development Engineer to join our Pyrolysis Test Engineering team. Reporting to the Director of Pyrolysis, you will lead the development and scale-up of next-generation biomass conversion processes from pilot testing through commercial deployment. You will define experimental strategy, drive resolution of complex scale-up challenges, and provide technical leadership across R&D, Engineering, and Operations teams.

This role requires deep process engineering expertise, strong technical judgment, and the ability to translate ambiguous experimental findings into robust, scalable industrial processes.

 
Your Responsibilities

  • Lead development of next-generation Charm pyrolyzers and biomass conversion processes to maximize bio-oil yield, product quality, reliability, and economic performance.

  • Define test plans and experimental campaigns that address critical technical uncertainties and inform commercialization decisions.

  • Own investigation and resolution of complex process performance, operability, and scale-up challenges across pilot and demonstration systems.

  • Develop and validate process models, material and energy balances, and engineering analyses to guide process improvements and future facility design.

  • Lead interpretation and communication of experimental results to technical and non-technical stakeholders, including recommendations for strategic development priorities.

  • Prepare and review process engineering documentation including Process Flow Diagrams (PFDs), Piping and Instrumentation Diagrams (P&IDs), Process Control Narratives (PCNs), Standard Operating Procedures (SOPs), and process equipment specifications.

  • Lead or facilitate process safety activities including Hazard and Operability study (HAZOP), Failure Mode and Effects Analysis (FMEA), Management of Change (MOC) reviews, and commissioning/startup readiness reviews.

  • Partner closely with Mechanical, Automation, Electrical, Manufacturing, and Operations teams to ensure successful deployment and operation of new process technologies.

  • Mentor junior engineers and contribute to the development of engineering standards, best practices, and technical culture across the organization.

  • Support our 24/7 operations through a rotating after-hours coverage schedule, totaling approximately 2-3 weeks per year.

You Bring

  • Bachelor's degree in Chemical Engineering, Mechanical Engineering, or a related field.

  • 7+ years of experience in process development engineering, or scale-up engineering, including significant experience operating and developing pilot-scale systems.

  • Demonstrated success scaling chemical, thermochemical, energy, or industrial process technologies from pilot through commercial deployment.

  • Deep understanding of heat transfer, reaction engineering, mass and energy balances, process controls, process safety, and industrial operations.

  • Strong hands-on troubleshooting skills and the ability to diagnose complex process and equipment failures in ambiguous environments.

  • Experience leading cross-functional technical projects involving multiple engineering disciplines.

  • Excellent written and verbal communication skills, including the ability to influence technical direction and align diverse stakeholders.

  • Strong engineering judgment and ability to balance technical rigor, operational realities, schedule, and cost.

  • Excitement for scaling industrial technologies that can meaningfully impact climate change.

Bonus if you Bring

  • M.S. or Ph.D. in Chemical Engineering, Mechanical Engineering, or a related field.

  • Experience with pyrolysis, gasification, biomass conversion, refining, petrochemicals, renewable fuels, or other thermochemical processing technologies.

  • Experience commissioning and operating industrial process systems at demonstration or commercial scale.

  • Experience leading process hazard analyses and implementing process safety management programs.

  • Experience managing external engineering partners, equipment vendors, or contract manufacturers.

$98,400 - $147,600 a year
What We Offer
  • Equity ownership through stock options
  • 100% employee healthcare premiums covered
  • Comprehensive medical, dental, and vision coverage with multiple plan options
  • Employer-funded HSA contributions for eligible HDHP plans
  • Traditional and Roth 401(k) with a 50% match on contributions up to 6%
  • Paid leave, including parental and medical leave
  • PPE and workwear allowances
  • Annual professional development stipend
  • Employee recognition programs that celebrate impactful work and team contributions
  • Opportunities for internal growth, career development, and transition into climate from a range of industries and backgrounds
 
Visa Sponsorship Policy
 
Since we are a small startup, certain accommodations for visa sponsorship may not be within our capability. At this time, Charm Industrial is only sponsoring E3 and TN visas.
 
Our Commitment
 
Charm Industrial is an equal opportunity employer. We hire based on skills, experience, and passion for our mission. Climate challenges require a wide range of perspectives and expertise, and we welcome applicants from all backgrounds. We're excited to grow our team with people who bring unique strengths and help us improve as a company.
 
At Charm, we may use AI-enabled tools to support certain aspects of the hiring process, including organizing candidate information and highlighting experience that may be relevant to a particular role. In a world where AI-assisted resumes, synthetic content, and deepfakes are increasingly common, these tools help our team navigate the process thoughtfully and efficiently. Every application and resume is reviewed by a member of our hiring team, and hiring decisions are made by people, not algorithms. Our recruiting process is designed to ensure candidates are evaluated fairly, consistently, and in alignment with our equal employment opportunity commitments. AI tools support our team's work, but they do not replace human judgment or determine hiring outcomes.
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