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Senior Process Development Engineer Jobs in Black Earth, WI

Collabera

SDET/ Automation Engineer

Madison, WI · On-site

Job Title: SDET/ Automation Engineer Location: Madison, WI or Bellevue, WA Duration: 6 Months ... Develop automated acceptance tests focused around user clinical workflow processes through analysis ...

The Panaro Group

R&D Engineer

Stoughton, WI · On-site

... processes, and other technical and economic factors. Essential Duties and Responsibilities ... Conceptual Design - Develop functional designs, in conjunction with support team of engineers ...

Stoughton Trailers, LLC

R&D Engineer

Stoughton, WI

... processes, and other technical and economic factors. Essential Duties and Responsibilities ... Conceptual Design - Develop functional designs, in conjunction with support team of engineers ...

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Senior Process Development Engineer information

See Black Earth, WI salary details

$76.8K

$124K

$174.5K

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

As of Sep 8, 2026, the average yearly pay for senior process development engineer in Black Earth, WI is $123,963.00, according to ZipRecruiter salary data. Most workers in this role earn between $106,400.00 and $137,700.00 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 cities near Black Earth, WI are hiring for Senior Process Development Engineer jobs?

Cities near Black Earth, WI 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 Black Earth, WI as of August 2026, with employment types broken down into 1% As Needed, 76% Full Time, 21% Part Time, and 2% Contract. Highlights an 86% Physical, 3% Hybrid, and 11% Remote job distribution, with an average salary of $123,963 per year, or $59.6 per hour.

Scientist - Process Development, Drug Substance Lifecycle

Catalent Pharma Solutions

Madison, WI

Full-time

Medical, Dental, Vision, Life, Retirement, PTO

Re-posted 2 hours ago

Key responsibilities

  • Lead process characterization activities for development, validation, and commercial-stage biologics programs.

  • Support process validation, continued process verification, comparability assessments, and lifecycle change management.

  • Collaborate with cross-functional teams to ensure successful technology transfer and support for commercial manufacturing.

Catalent rating

7.6

Company rating: 7.6 out of 10

Based on 55 frontline employees who took The Breakroom Quiz

61st of 86 rated pharmaceutical

Job description

Scientist - Process Development, Drug Substance Lifecycle

Catalent is seeking a Scientist - Process Development, Drug Substance Lifecycle to join our team in Madison, Wisconsin. In this role, you will provide technical expertise and lifecycle support for biologics programs as they progress through development, validation, commercialization, and post-approval manufacturing. You'll collaborate across Manufacturing, Quality, MS&T, Regulatory, Project Management, and client teams to drive successful program execution and continuous process improvement.

About Catalent Madison: Catalent's Madison, Wisconsin facility is a state-of-the-art biologics development and manufacturing site supporting customers from research through early- and mid-stage clinical production. Located at 726 Heartland Trail, the 102,700-square-foot GMP facility specializes in mammalian cell line engineering, drug substance manufacturing, and biopharmaceutical process development.

The site is home to Catalent's proprietary GPEx and GPEx Lightning technologies, enabling the generation of high-producing mammalian cell lines for biologic therapies. With production capabilities ranging from 50L to 4,000L and a recent $45 million expansion, the Madison campus continues to play a critical role in Catalent's global biologics network while supporting Wisconsin's growing life sciences industry.

Location: 100% Onsite at our facility in Madison, Wisconsin
Shift: Monday - Friday, First Shift

Key Responsibilities:

  • Lead process characterization activities for development, validation, and commercial-stage biologics programs.

  • Support process validation, continued process verification, comparability assessments, and lifecycle change management.

  • Analyze process performance data, identify improvement opportunities, and drive risk reduction initiatives.

  • Serve as a technical subject matter expert for assigned programs and client interactions.

  • Author and review technical protocols, reports, validation documents, and regulatory support documentation.

  • Support investigations, CAPAs, change controls, and quality system activities in a cGMP environment.

  • Collaborate with cross-functional teams to ensure successful technology transfer and commercial manufacturing support.

  • Other responsibilities as needed.

Required Qualifications:

  • PhD in a STEM discipline or Master's degree with a minimum of 3 years of relevant industry experience; or Bachelor's degree with a minimum of 6 years of relevant industry experience.

Preferred Qualifications:

  • Experience supporting biologics development, characterization, validation, or commercial manufacturing.

  • Knowledge of process characterization, PPQ, lifecycle management, and validation principles.

  • Experience working within cGMP environments.

  • Familiarity with statistical analysis tools such as JMP, Minitab, or Excel.

  • Experience supporting cross-functional technical projects and client-facing activities.

Why you should join Catalent:

  • Opportunity to play a key role in driving growth within a global CDMO leader.

  • Competitive compensation package, including incentive opportunity.

  • Day-one medical, dental, and vision coverage.

  • 401(k) with company match.

  • Tuition reimbursement and professional development opportunities.

  • Generous paid time off and holiday schedule (152 hours + 8 holidays)

  • Collaborative, mission-driven culture focused on improving patient outcomes worldwide.

Catalent offers rewarding opportunities to further your career! Join the global drug development and delivery leader and help us bring over 7,000 life-saving and life-enhancing products to patients around the world. Catalent is an exciting and growing international company where employees work directly with pharma, biopharma and consumer health companies of all sizes to advance new medicines from early development to clinical trials and to the market. Catalent produces more than 70 billion doses per year, and each one will be used by someone who is counting on us. Join us in making a difference.

personal initiative. dynamic pace. meaningful work.

Visit Catalent Careers to explore career opportunities.

Catalent is an Equal Opportunity Employer, including disability and veterans.

If you require reasonable accommodation for any part of the application or hiring process due to a disability, you may submit your request by sending an email, and confirming your request for an accommodation and include the job number, title and location to DisabilityAccommodations@catalent.com. This option is reserved for individuals who require accommodation due to a disability. Information received will be processed by a U.S. Catalent employee and then routed to a local recruiter who will provide assistance to ensure appropriate consideration in the application or hiring process.

Notice to Agency and Search Firm Representatives: Catalent Pharma Solutions (Catalent) is not accepting unsolicited resumes from agencies and/or search firms for this job posting. Resumes submitted to any Catalent employee by a third party agency and/or search firm without a valid written & signed search agreement, will become the sole property of Catalent. No fee will be paid if a candidate is hired for this position as a result of an unsolicited agency or search firm referral. Thank you.

Important Security Notice to U.S. Job Seekers:

Catalent NEVER asks candidates to provide any type of payment, bank details, photocopies of identification, social security number or other highly sensitive personal information during the offer process, and we NEVER do so via email or social media. If you receive any such request, DO NOT respond- it is a fraudulent request. Please forward such requests to spam@catalent.com for us to investigate with local authorities.

California Job Seekers can find our California Job Applicant Notice HERE.

What Catalent employees say

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About Catalent

Sourced by ZipRecruiter

Catalent is an exciting and growing international company where employees work directly with pharma, biopharma and consumer health companies of all sizes to advance new medicines from early development to clinical trials and to the market. Catalent produces more than 70 billion doses per year, and each one will be used by someone who is counting on us. Join us in making a difference.Catalent is committed to the health and safety of its employees, visitors and the customers and patients we serve.

Industry

Pharmaceutical product wholesalers

Company size

10,000+ Employees

Headquarters location

Somerset, NJ, US

Year founded

2007

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