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Senior Process Development Engineer Jobs in Birmingham, AL

Imerys

Senior Process Engineer

Sylacauga, AL · On-site

$84K - $109K/yr

As part of its commitment to responsible development, Imerys promotes environmentally friendly ... The Position Senior Process Engineer Job Summary At Imerys, we are the world leader in mineral ...

J.M. Smucker Company

Senior Engineer, Process

Mccalla, AL

$94K - $121K/yr

As a Senior Process Engineer , you'll lead manufacturing improvements across Sandwich Making and ... Partner with Operations, Engineering, and R&D to evaluate and implement new products, processes ...

Croda

Lead Process Development Scientist

Alabaster, AL · On-site

Bachelor's degree or higher in Chemistry, Chemical Engineering, Pharmaceutical Sciences, or a related scientific discipline. * Eight (8) + years of plant and process development experience within ...

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All JobsProcess Development Engineer JobsSenior Process Development Engineer JobsSenior Process Development Engineer Jobs in Birmingham, AL

Senior Process Development Engineer information

See Birmingham, AL salary details

$70.3K

$113.5K

$159.8K

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

As of Sep 7, 2026, the average yearly pay for senior process development engineer in Birmingham, AL is $113,509.00, according to ZipRecruiter salary data. Most workers in this role earn between $97,500.00 and $126,100.00 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 Birmingham, AL?

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

What job categories do people searching Senior Process Development Engineer jobs in Birmingham, AL look for?

The top searched job categories for Senior Process Development Engineer jobs in Birmingham, AL are:

What cities near Birmingham, AL are hiring for Senior Process Development Engineer jobs?

Cities near Birmingham, AL 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 Birmingham, AL as of August 2026, with employment types broken down into 1% As Needed, 79% Full Time, 17% Part Time, and 3% Contract. Highlights an 86% Physical, 3% Hybrid, and 11% Remote job distribution, with an average salary of $113,421 per year, or $54.5 per hour.

Senior Process Engineer

Imerys

Sylacauga, AL • On-site

$84K - $109K/yr

Full-time

Posted 4 days ago

Imerys rating

7.4

Company rating: 7.4 out of 10

Based on 19 frontline employees who took The Breakroom Quiz

20th of 41 rated mining

Job description

The Company
Imerys is the world's leading supplier of mineral-based specialty solutions for the industry with €3.4 billion in revenue and 12,300 employees in 40 countries in 2025. The Group offers high value-added and functional solutions to a wide range of industries and fast-growing markets such as solutions for the energy transition and sustainable construction, as well as natural solutions for consumer goods. Imerys draws on its understanding of applications, technological knowledge, and expertise in material science to deliver solutions which contribute essential properties to customers' products and their performance. As part of its commitment to responsible development, Imerys promotes environmentally friendly products and processes in addition to supporting its customers in their decarbonization efforts.
Imerys is listed on Euronext Paris (France) with the ticker symbol NK.PA.
The Position
Senior Process Engineer
Job Summary
At Imerys, we are the world leader in mineral-based specialty solutions, and our Sylacauga plant is at the heart of our operations. We are seeking a highly motivated Senior Process Engineer to serve as the technical anchor for our manufacturing processes.
In this role, you won't just maintain the status quo-you will drive the innovation and engineering required to optimize existing systems and commission new technologies. If you are passionate about applying continuous improvement methodologies, solving complex production challenges, and mentoring the next generation of engineers, we want you on our team.
What You Will Do
Drive Process Innovation & Profitability
  • Optimize Operations: Spearhead plant productivity initiatives using Six Sigma, Lean Manufacturing, and fundamental Chemical Engineering principles.
  • Maximize Efficiency: Target and execute improvements focused on debottlenecking, yield maximization, operating efficiency, and product quality.
  • Quantify Impact: Prepare rigorous financial and economic analyses for process improvements to determine business impact and prioritize capital projects.

Lead Engineering & Project Execution
  • End-to-End Design: Develop required designs within the engineering discipline, including feasibility studies, basic engineering plans, and cost estimates.
  • Hands-On Execution: Supervise and execute plant trials, directly participate in commissioning new process technologies, and troubleshoot complex daily production issues.
  • Equip the Plant: Evaluate, specify, and select equipment and materials to ensure long-term operational reliability.

Provide Technical Leadership
  • Mentor: Provide technical guidance and mentorship to Junior Process Engineers, helping build a world-class engineering team.
  • Collaborate: Act as the technical bridge between technology and business, quantifying and clearly communicating process advancements to Management, Production, Maintenance, and Administrative teams.
  • Champion Customers: Participate in-and often lead-customer process improvement teams to ensure our solutions exceed market expectations.
What You Bring to the Team
  • Education: A Bachelor of Science (BS) degree in Industrial Engineering, Chemical Engineering, or a closely related field.
  • Experience: Minimum 3 to 5 years of proven engineering experience in an industrial or manufacturing environment.
  • Skills: Strong project management background with a track record of driving process improvements from concept to completion.
The Work Environment
This is a dynamic, hands-on role where you will spend time both analyzing data and getting involved on the production floor.
  • Environment: Work is split between the laboratory, office, and active process/production areas.
  • Physicality: You can expect to be on your feet (standing/walking) up to 60% of the time, with occasional climbing (up to 10%) and lifting up to 25 pounds as you interact directly with our plant systems.

Position Type
Full time
and
Permanent
Only technical issues will be monitored through the below inbox:
recruiting.support@ imerys.com
PLEASE DO NOT SUBMIT RESUMES OR APPLICATIONS TO THIS EMAIL, AS THEY WILL NOT BE REVIEWED.
To ensure fairness and legal compliance in our recruitment processes, only applications received through the online application process will be considered.
IMERYS is an Affirmative Action and Equal Opportunity Employer and it is our policy to not discriminate against any employee or applicant for employment because of race, color, religion, sex, national origin, age, marital status, sexual orientation, gender identity, genetic information, disability, veteran status, or any other status protected by federal, state or local laws.

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