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Senior Process Development Engineer Jobs in Connecticut

PTA Plastics

Sr. Process Engineer

Oxford, CT · On-site

$120K - $135K/yr

Lead mold sampling, process development, validation activities, and production launches. * Work with Quality to establish and maintain consistent part quality, process controls, and monitoring ...

ASML

Senior Process Engineer - MRF

Wilton, CT · On-site

$107K - $139K/yr

This role is responsible for process development, stabilization, and daily performance across CNC ... The Senior Process Engineer will operate as a technical leader within Wilton Factory Optics with ...

ASML

Senior Process Engineer - Optical Fabrication

Wilton, CT · On-site

$107K - $139K/yr

This role is responsible for process development, stabilization, and daily performance across ... The Senior Process Engineer will operate as a technical leader within Optical Fabrication with end ...

King Industries Inc.

Senior Process Engineer

Norwalk, CT · On-site

$104K - $135K/yr

KING INDUSTRIES Senior Process/Project Engineer Location - Norwalk, CT King Industries is seeking a Senior Process/Project Engineer to join our Engineering team. The ideal candidate will have a ...

Wieland

Sr. Process Engineer

Waterbury, CT · On-site

$100K - $115K/yr

The Sr. Process Engineer will be responsible for improving production processes and the quality of the material to manufacture copper and stainless steel-alloy strips cost effectively. This role is ...

Wieland

Sr. Process Engineer

Waterbury, CT · On-site

$100K - $115K/yr

The Sr. Process Engineer will be responsible for improving production processes and the quality of the material to manufacture copper and stainless steel-alloy strips cost effectively. This role is ...

Wieland

Sr. Process Engineer

Waterbury, CT

$100K - $115K/yr

The Sr. Process Engineer will be responsible for improving production processes and the quality of the material to manufacture copper and stainless steel-alloy strips cost effectively. This role is ...

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All JobsProcess Development Engineer JobsSenior Process Development Engineer JobsSenior Process Development Engineer Jobs in Connecticut

Senior Process Development Engineer information

See Connecticut salary details

$71.3K

$115.2K

$162.2K

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 Connecticut is $115,216.00, according to ZipRecruiter salary data. Most workers in this role earn between $98,900.00 and $127,900.00 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 Connecticut?

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

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

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

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

Cities in Connecticut 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 Connecticut as of August 2026, with employment types broken down into 1% As Needed, 81% Full Time, 14% Part Time, 2% Temporary, and 2% Contract. Highlights an 86% Physical, 3% Hybrid, and 11% Remote job distribution, with an average salary of $115,216 per year, or $55.4 per hour.

Sr. Process Engineer

PTA Plastics

Oxford, CT • On-site

$120K - $135K/yr

Full-time

Re-posted 16 days ago

Job description

Company Overview:
PTA Plastics, an employee-owned and innovative leader in the plastic injection molding, contract manufacturing and tool-building industry, is looking for a Senior Process Engineer to join our dynamic team.
At PTA Plastics, we're more than just a manufacturer; we partner with Fortune 500 OEMs in the medical device, defense, homeland security, and technology sectors, constantly pushing the boundaries of product development and manufacturing excellence. As an employee-owned company, every team member has a stake in our success, creating a collaborative and entrepreneurial environment where innovation thrives.
Job Summary:
The Senior Process Engineer plays a vital role in the injection molding team by creating, analyzing, improving, and adjusting molding processes to optimize cost, quality, and throughput of the molding operations. The Molding Process Engineer will be responsible for sampling, process development, and documentation of new injection molds as well as existing molds; in addition to mold validation and sampling.
Pay: $120,000 - $135,000 annually
Essential Duties/Responsibilities:
  • Develop and optimize injection molding processes for new and existing molds using scientific molding principles.
  • Lead mold sampling, process development, validation activities, and production launches.
  • Work with Quality to establish and maintain consistent part quality, process controls, and monitoring systems.
  • Troubleshoot molding processes, tooling, materials, automation, and equipment issues.
  • Collect and analyze process data to identify opportunities to improve quality, efficiency, cycle time, and process capability.
  • Document and maintain process sheets, setup standards, work instructions, and validation documentation.
  • Assist with the creation and maintenance of Control Plans, PFMEAs, process flows, and related manufacturing documentation.
  • Participate in mold design reviews, material reviews, and formal print reviews.
  • Provide input on mold, tooling, automation, and equipment designs to ensure alignment with process requirements and manufacturing objectives.
  • Develop and execute Design of Experiments (DOE), capability studies, and process validations for new and modified processes.
  • Provide technical leadership and support for cost reduction, scrap reduction, cycle time improvement, and continuous improvement initiatives.
  • Work with Operations, Tooling, Maintenance, Engineering, and Quality to develop, strengthen, and maintain troubleshooting and process improvement activities.

  • Serve as a technical resource for resolving molding defects, dimensional issues, and process-related production challenges.
  • Mentor and train Process Technicians, Setup Technicians, and Operations personnel on scientific molding and process control practices.
  • Use Lean Manufacturing, Six Sigma (DMAIC), SPC, DOE, and other statistical tools to analyze process performance and drive continuous improvement.
  • Support KPI tracking and reporting related to scrap, efficiency, downtime, OEE, cycle time, and process capability.
  • Other duties as assigned.

Qualifications & Requirements:
  • Bachelor's degree in Engineering (Manufacturing, Mechanical, Plastics, Industrial) and
  • 8+ years of hands-on process engineering experience in plastics manufacturing, with strong injection molding expertise
  • 5+ years of experience with ISO 13485 or similar regulated industry quality system requirements preferred
  • Demonstrated experience developing, documenting, optimizing, and troubleshooting injection molding processes in a production environment.
  • Strong knowledge of scientific molding, decoupled molding, process window development, tooling, resins, drying requirements, and secondary operations.
  • Experience with mold sampling, process validation, capability studies, root cause analysis, corrective/preventive actions (CAPA), and MRB support.
  • Experience using Computer Aided Design (CAD) software; experience with Moldflow, RJG/eDART, cavity pressure monitoring, or similar tools is preferred.
  • Working knowledge of Lean Manufacturing, Six Sigma, DOE, SPC, GD&T, PFMEA, control plans, ERP/MES systems, and data analysis tools.
  • Strong communication, leadership, mentoring, problem-solving, and project management skills with the ability to influence cross-functional teams.
  • Experience in writing, reading and interpreting the documentation of designs and production processes.

Physical Requirements:
  • Ability to stand, walk, and move around the production floor for extended periods.
  • Capable of lifting and carrying heavy objects weighing up to 50 pounds.
  • Manual dexterity and hand-eye coordination for handling small tools, machine components, and molds.
  • Ability to work in a fast-paced environment and adapt to changing priorities.
  • Comfortable wearing personal protective equipment (PPE) such as safety glasses, gloves, and ear protection.
  • Occasional bending, kneeling, and reaching to access equipment and perform maintenance tasks.
  • Good vision and color perception for inspecting parts and identifying any defects or abnormalities.
  • Ability to work in temperature-controlled environments and withstand exposure to noise levels associated with manufacturing machinery.
  • Ability to receive, comprehend and utilize required training from OSHA and Company including but not limited to the following:
  • Hazard Communication
  • Lock Out/Tag Out

Equal Employment Opportunity & ADA Compliance Statement:
PTA Plastics is committed to providing equal employment opportunities to all individuals, including those with disabilities. As part of this commitment, PTA Plastics complies with the Americans with Disabilities Act (ADA)andConnecticut's Fair Employment Practices Act (CFEPA), which prohibit discrimination against individuals with disabilities in hiring, job assignments, promotions, compensation, benefits, training, and other aspects of employment.
If you require a reasonable accommodation to participate in the application or interview process or to perform the essential functions of this position, please contact HR@ptaplastics.com. Reasonable accommodations will be provided in accordance with applicable laws to enable individuals with disabilities to perform essential job duties.
This job description is intended to describe the general nature and level of work being performed. It is not an exhaustive list of all responsibilities, duties, and skills required. Employees may be required to perform other duties as assigned.

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