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Senior Process Development Engineer Jobs in Malvern, PA

Genesis AEC

Senior Process Engineer

Blue Bell, PA

$99K - $128K/yr

SENIOR PROCESS ENGINEER Do you have an innate curiosity when it comes to learning, implementing ... This position provides opportunities for personal development and growth as well as supporting and ...

Genesis AEC

Senior Process Engineer

Blue Bell, PA · On-site

$99K - $128K/yr

SENIOR PROCESS ENGINEER Do you have an innate curiosity when it comes to learning, implementing ... This position provides opportunities for personal development and growth as well as supporting and ...

PM Group

Senior Process Engineer

Conshohocken, PA · On-site

$102K - $132K/yr

Overview The Senior Process Engineer position is an exciting opportunity to join PM Group's quickly ... Mass Balance, PFD and P&ID development for typical biopharmaceutical process unit operations ...

PM Group

Senior Process Engineer

Conshohocken, PA · On-site

$102K - $132K/yr

The Senior Process Engineer is mentored by more senior level engineering team members and, conversely, will be involved with the mentoring and development of less experienced process engineering team ...

Wood Plc

Senior Process Engineer

Philadelphia, PA · On-site +1

$104K - $135K/yr

Overview / Responsibilities Senior Process Engineer (Life Sciences) Wood is currently seeking a ... Participating in project planning, cost development, and project scheduling * Maintaining effective ...

Keystone Engineering Group

Senior Process Engineer

Frazer, PA · Hybrid

$102K - $132K/yr

Senior Process Engineer Keystone Engineering Group, Inc. is a Professional Engineering Firm and ... Training, Professional Development and Career Pathing * Casual Dress Code * Employee Referral Bonus

Veranova

Senior Process Safety Engineer

West Deptford, NJ · On-site

$120 - $125/hr

Senior Process Safety Engineer Full Time - Salary West Deptford, NJ, US 4 days ago Requisition ID ... Veranova is a global leader in the development and manufacturing of complex active pharmaceutical ...

eZone Staffing LLC

Be Seen First

Senior Process Engineer

Frazer, PA · On-site

$109K - $136K/yr

Training, Professional Development and Career Pathing * Casual Dress Code * Employee Referral Bonus ... Our Engineers travel locally to client sites and occasionally have overnight travel trips for ...

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All JobsProcess Development Engineer JobsSenior Process Development Engineer JobsSenior Process Development Engineer Jobs in Malvern, PA

Senior Process Development Engineer information

See Malvern, PA salary details

$73.6K

$118.8K

$167.3K

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

As of Sep 5, 2026, the average yearly pay for senior process development engineer in Malvern, PA is $118,848.00, according to ZipRecruiter salary data. Most workers in this role earn between $102,100.00 and $132,000.00 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 Malvern, PA?

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

What cities near Malvern, PA are hiring for Senior Process Development Engineer jobs?

Cities near Malvern, PA 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 Malvern, PA as of August 2026, with employment types broken down into 100% Full Time. Highlights an 70% In-person, 10% Hybrid, and 20% Remote job distribution, with an average salary of $118,848 per year, or $57.1 per hour.

Senior Process Engineer

Genesis AEC

Blue Bell, PA

$99K - $128K/yr

Full-time

Medical, Dental, Vision, Retirement, PTO

Re-posted 21 days ago

Job description

SENIOR PROCESS ENGINEER
Do you have an innate curiosity when it comes to learning, implementing, and integrating the different pieces of a design puzzle? Are you seeking the next step in your career that offers significant growth potential?
If so, we invite you to apply for our exceptional team as a Senior Process Engineer!
WHO WE ARE:

We’re Genesis AEC – an award-winning architecture, engineering, construction management, and CQV firm and a leader in the life sciences industry. Ranked #5 in Pharmaceutical Design by ENR magazine, we’re designing and constructing facilities that advance worldwide health. We’re proud to contribute to our Clients’ success, earning honors that include a 2021 ISPE Facility of the Year (FOYA) award and an ENR Mid-Atlantic’s Best Manufacturing Project award for our work at the National Institutes of Health.
Our culture is based on inclusion, one where all identities, backgrounds, and perspectives are embraced. When you’re on our team, you’ll find you are supported, challenged, and encouraged to grow – with opportunities, training, and a work-life balance to help you succeed.
This is a tremendous opportunity for a dedicated individual who wants to lead the process discipline on high-visibility projects. This position provides opportunities for personal development and growth as well as supporting and mentoring junior process engineers. The responsibilities of this position include leading process projects across a broad range of potential process types, with a high-level focus on areas such as biotechnology, oral solid dosage, and aseptic processing – each with its own diverse subsets of process types. Based on experience, a preferred area of expertise can be targeted or a range of assignments can be provided to support overall growth and flexibility. Our collaborative culture ensures that our clients benefit from top-tier work across our entire range of professional offerings.
WHAT YOU WILL BE DOING

The Senior Process Engineer will be client-facing and support front-end project definition through facilitated client engagement. The process engineer begins by understanding and assessing client process requirements, including infrastructure impacts, and supporting the design of cGMP-compliant facilities that meet these requirements. The engineer will develop project deliverables that represent scope understanding and drive overall project definition. The Senior Process Engineer will effectively collaborate with other disciplines, starting with architecture, to support the development of initial adjacency diagrams and facility layouts. This is followed by communications with process utilities, mechanical, electrical, and plumbing disciplines to support overall facility infrastructure design.
The ideal candidate will determine how to add value given each project’s unique circumstances – knowing when to employ production simulation tools for right-sizing of the facility based on required throughput; providing sound recommendations for efficient and effective operations backed up by modeling and calculations; and providing solutions that address the project’s given challenges.
A Senior Process engineer should be conversant with the design and specification of cGMP systems and equipment. Client interface skills, communication skills, delegation of tasks, and leadership skills are required for this position. This role also includes proposal preparation and sales presentations to potential clients.
Senior Process Engineer
Responsibilities / Role Expectations
  • Develop and maintain typical process engineering deliverables, including but not limited to: Block/Process Flow Diagrams, Mass Balances, Process Equipment Lists, Utility Summaries, P amp;IDs, Equipment Specification packages, Process Simulation modeling, Hydraulic calculations, line sizing, equipment sizing, etc.
  • Execute and/or direct the development of calculations or process simulations as necessary to support the process design effort.
  • Lead or participate in Process Hazard Analyses (PHAs) and regulatory or quality Risk Assessments.
  • Assist in the development of documents for inclusion in construction packages (e.g., system descriptions, BODs, URS’s, flow diagrams, material and energy balances, P amp;IDs, datasheets, and equipment specifications)
  • Collaborate with Process Automation to support the development of and review the creation of process automation concepts and determine instrumentation requirements.
  • Ensure that other project disciplines (e.g., architectural, process utilities, mechanical, electrical, plumbing) understand the applicable process requirements and interfaces.
  • Ensure designs are compliant with regulatory (e.g., FDA, EU Annex 1) and industry (e.g., ISPE, BPE) requirements and guidance.
  • Ensure designs are compliant with environmental and safety practices.
Operations
  • Lead process-driven projects independently or manage a small team of process engineers on more complex projects.
  • Support a range of projects at any project phase, from feasibility through detailed design and construction support.
  • Define process requirements, lead client engagement, and develop process understanding deliverables.
  • Guide junior and mid-level process engineers in the development of deliverables.
  • Delegate assignments to process staff and guide their work.
Client Facing
  • Assess and analyze data, integrate, and lead the development of concepts to create designs and/or reports.
  • Develop and provide solutions for clients that optimize operations, facility flows, and utility consumption.
  • Direct the collection of appropriate data from clients to develop/define process requirements and clearly document design basis for collaboration/development
  • Present results and recommendations to clients; assist in gathering input and feedback to strengthen designs.
  • Facilitate and document workshops, including Risk Assessments and Process Hazard Analyses.
  • Lead client interface and provide project management when required.
  • Some local travel to Client Sites is expected, as needed. Limited national travel could be required.
Strategic
  • Prepare scope and hourly estimates for various process work in preparation for client proposals.
  • Ability to assist with Business Development by nurturing client relationships and identifying potential project opportunities.
  • Prepare process design plan per project, including resource requirements and execution plan to complete design.
  • Perform quality checks of work completed by others on the process team.
  • Stay current with EU and FDA regulations and trends regarding ever-changing regulatory requirements of pharmaceutical manufacturing.
  • Collect information from industry sources to help clarify design and industry best practices
  • Recruit lead engineers and process engineers to continue to enhance and expand the Process Department at Genesis.
YOU MAY BE A GOOD FIT IF YOU MEET THESE REQUIREMENTS

Minimum Qualifications:
  • BS in Chemical Engineering or Mechanical Engineering
  • 10+ years of experience associated with the design and development of cGMP operations and equipment in the Life Sciences industry.
  • Experience with the design and/or operation of cGMP manufacturing systems.
  • Ability to effectively communicate process concepts to clients and peers
  • Intermediate to advanced level skills with Microsoft Office software
  • Strong written and oral communication skills
  • Ability to work well under pressure and to prioritize multiple projects while adjusting work against deadlines

Preferred Qualifications:
  • Experience with cGMP design in both the A amp;E business and operating company in the Life Sciences industry.
  • General experience across a range of processes (biotech, API, OSD, aseptic processing, etc.) or proven and demonstrated expertise in one or more areas of pharmaceutical manufacturing.
  • Experience with Supervisory Control and Data Acquisition (SCADA) systems, including a basic understanding of how to apply such systems on a process-driven project.
  • Published author regarding cGMP design or a desire to do so in the future.
  • ISPE and/or PDA involvement/leadership.
  • P.E. Registration or a path toward licensure.

WHY YOU’LL LOVE IT HERE:
  • Our collaborative and positive culture sets us apart
  • We offer hybrid work schedules and half-day Fridays year-round.
  • Comprehensive medical, dental, vision, and RX insurance plans, with two-thirds of your premiums and deductible paid!
  • Competitive 401k match program
  • Generous paid time off
  • Paid parental leave time
  • Thought leadership opportunities, including a $1,000 award for presenting or publishing your technical expertise!
  • Competitive company-paid training opportunities
  • A 5% salary increase for earning your professional license!
  • Endless opportunities to grow your career
  • And so much more!

Are you ready to unlock your potential with us? With your passion and our vision, there's no limit to what you can accomplish here! Submit your resume today for immediate consideration.

Apply