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Senior Process Development Engineer Jobs in Madison, WI

Placon Corporation

Process Engineer

Madison, WI · On-site

$70K - $85K/yr

A hands-on technical role where your engineering expertise truly matters ... Opportunities to grow your skills in new product development, process control, and capital ...

Placon Corporation

Process Engineer

Madison, WI · On-site

$70K - $85K/yr

Process EngineerWe're looking for a dependable Process Engineer who will be located in our Madison ... product development, and driving continuous improvement. If you have strong analytical skills ...

Placon Corporation

Process Engineer

Madison, WI · On-site

$70K - $85K/yr

A handson technical role where your engineering expertise truly matters ... Opportunities to grow your skills in new product development, process control, and capital ...

SHINE Technologies LLC

Senior R&D Chemist

Janesville, WI · On-site

$75K - $120K/yr

The role of the Senior R&D Chemist plays a critical part in radiochemical process development and ... Work closely with multidisciplinary teams in chemistry, process engineering, and licensing to ...

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Showing results 21-40

All JobsProcess Development Engineer JobsSenior Process Development Engineer JobsSenior Process Development Engineer Jobs in Madison, WI

Senior Process Development Engineer information

See Madison, WI salary details

$75.6K

$122K

$171.8K

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

As of Aug 7, 2026, the average yearly pay for senior process development engineer in Madison, WI is $122,040.00, according to ZipRecruiter salary data. Most workers in this role earn between $104,800.00 and $135,500.00 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 Madison, WI? For Senior Process Development Engineer jobs in Madison, WI, the most frequently searched job titles are:
What job categories do people searching Senior Process Development Engineer jobs in Madison, WI look for? The top searched job categories for Senior Process Development Engineer jobs in Madison, WI are:
Senior Process Development Engineer jobs near you
Infographic showing various Senior Process Development Engineer job openings in Madison, WI as of August 2026, with employment types broken down into 1% As Needed, 80% Full Time, 15% Part Time, and 4% Contract. Highlights an 92% Physical, 2% Hybrid, and 6% Remote job distribution, with an average salary of $122,040 per year, or $58.7 per hour.

Process Engineer

Placon Corporation

Madison, WI • On-site

$70K - $85K/yr

Full-time

Re-posted 6 days ago

Placon rating

5.8

Company rating: 5.8 out of 10

Based on 7 frontline employees who took The Breakroom Quiz

72nd of 84 rated plastic manufacturers

Job description

Process Engineer
We're looking for a dependable Process Engineer who will be located in our Madison, WI facility that thrives in a fast-paced GMP manufacturing environment and takes pride in developing reliable processes, supporting new product development, and driving continuous improvement. If you have strong analytical skills, mechanical understanding, and a passion for improving manufacturing performance, this is a great opportunity to make an impact.
Compensation
  • Commensurate with experience, the range is $70,000 - 85,000 annually.

Work Schedule
  • Onsite: 8 AM - 5 PM | Monday - Friday

Why Placon - You'll Love It Here
  • A hands-on technical role where your engineering expertise truly matters
  • Opportunities to grow your skills in new product development, process control, and capital equipment projects
  • A supportive manufacturing environment with modern equipment and advanced technology
  • Competitive pay, great benefits, and a stable onsite Monday-Friday schedule
  • A culture focused on safety, quality, and continuous improvement

What You'll Do
  • Devise and execute plans to qualify new products and materials
  • Support capital equipment projects by becoming an onsite expert in process and equipment
  • Improve production efficiency by analyzing process control trends and troubleshooting issues
  • Use Lean, Six Sigma, and other tools to identify and implement continuous improvement opportunities
  • Collect and analyze data; present recommendations through formal reports and presentations
  • Coordinate with planning and design teams to ensure product and tooling deadlines are met
  • Construct and maintain technical documents, specifications, and data sheets
  • Establish and review product standards for material, labor, and equipment
  • Maintain understanding of ISO quality systems as they relate to process development
  • Write proposals for capital expenditures and obtain approval

What You Bring
  • Bachelor of Science in Chemical, Materials, Mechanical, or related engineering field
  • Excellent written and verbal communication skills
  • Strong cross-functional teamwork and project management abilities
  • Technical competency in polymer materials, processing, and testing
  • Understanding statistical analysis and process capability
  • Strong problem-solving and troubleshooting skills
  • Experience in a manufacturing environment with knowledge of machine components and equipment
  • Ability to learn and utilize ERP and QMS systems
  • Knowledge of Lean, Six Sigma, and modern manufacturing methods
  • Ability to lift 10-50 lbs., stand for long periods, and travel as needed
  • Self-starter mindset with strong organization, time management, and attention to detail

Does this sound like you?
If you feel that this job is what you're looking for, applying is a piece of cake - just follow the instructions on this page. Good luck!
This job description reflects the current assignment of essential accountabilities and is not meant to be all-inclusive. Duties and responsibilities may be assigned or reassigned to this job at any time and may be modified to reasonably accommodate an individual with a disability or for other reasons.
Placon employment offers are contingent upon the successful completion of a pre-employment drug test, basic physical, background check, educational verification, and reference checks (as applicable).
Placon requires that employees have and maintain authorization to work in the country in which the role is based. In general, Placon does not sponsor candidates for non-immigrant visas or permanent residency unless based on business need.
Placon is committed to equal opportunity for all applicants without regard to race, color, religion, sex, sexual orientation, gender, gender identity, or expression, marital status, age, national origin, disability, veteran status, genetic information, or other protected characteristics.
This role requires the ability to work through differing perspectives and resolve conflict in a respectful and professional manner consistent with The Placon Way.

What Placon employees say

Pay

Hours and flexibility

Workplace

Get the full story on Breakroom

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About Placon

Sourced by ZipRecruiter

Industry

Plastics packaging film and sheet (including laminated) manufacturing

Company size

201 - 500 Employees

Headquarters location

Fitchburg, WI, US

Year founded

1966

Social media

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