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Senior Process Development Engineer Jobs in Philadelphia, PA

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Senior Process Development Engineer information

See Philadelphia, PA salary details

$75.7K

$122.2K

$172.1K

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

As of Aug 17, 2026, the average yearly pay for senior process development engineer in Philadelphia, PA is $122,217.00, according to ZipRecruiter salary data. Most workers in this role earn between $104,900.00 and $135,700.00 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 are popular job titles related to Senior Process Development Engineer jobs in Philadelphia, PA?

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

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

The top searched job categories for Senior Process Development Engineer jobs in Philadelphia, PA are:

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

Cities near Philadelphia, 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 Philadelphia, PA as of August 2026, with employment types broken down into 1% As Needed, 76% Full Time, 18% Part Time, 1% Temporary, and 4% Contract. Highlights an 91% Physical, 3% Hybrid, and 6% Remote job distribution, with an average salary of $122,217 per year, or $58.8 per hour.

Sr Process Technology Engineer - High Pressure Processing

Engineers and Constructors International Inc.

Philadelphia, PA • On-site

$104K - $135K/yr

Full-time

Posted 17 days ago

Job description

Our client, a highly respected U.S.-based specialty chemical manufacturer with more than 60 years of industry leadership, has created a new Sr Process Technology Engineer - High Pressure Processing position at their Pennsylvania headquarters.
In this highly visible position, you will serve as the company's primary technical resource for high-pressure processing and reactor technologies, partnering with Operations, R&D, Maintenance, Quality, and Engineering teams to improve manufacturing performance and support long-term growth initiatives.  This role ensures safe, reliable, and efficient high-pressure processing operations, including equipment improvements, scale-up, troubleshooting, capital projects, and technology transfer.
This role represents a significant investment in expanding their technical capabilities and commercializing next-generation products across highly regulated and performance-critical markets.  Success will be measured by improved high-pressure processing reliability and performance, successful commercialization, effective project execution, and stronger internal technical expertise.
Key Areas of Responsibility
High-Pressure Processing & Equipment
Serve as the primary engineering resource for high-pressure processing and reactor systems by troubleshooting process and equipment issues, evaluating performance, recommending improvements to safety, reliability, productivity, and scalability, developing preventive maintenance and lifecycle plans, supporting inspections, repairs, modifications, commissioning, startups, shutdowns, and process trials, and monitoring performance to drive continuous improvement.
Process Scale-Up & Commercialization
Lead technology transfer, process scale-up, operating parameter optimization, validation, and commercialization efforts to improve product quality, consistency, throughput, and manufacturing efficiency.
Engineering Projects
Lead reactor-related capital and engineering projects from concept through implementation, including scope, specifications, budgets, schedules, vendor evaluation, procurement, installation, commissioning, qualification, and cross-functional coordination.
Quality Systems & Documentation
Support quality system requirements within ISO 13485 by managing engineering changes, maintaining technical and validation documentation, participating in risk assessments, supporting CAPA and related investigations, and ensuring compliance with company procedures and applicable regulations.
Collaboration & General Engineering Support
Partner cross-functionally with Operations, Maintenance, R&D, Quality, EHS, Supply Chain, and Engineering to resolve technical challenges, provide guidance and training to manufacturing teams, share project updates with stakeholders, customers, and partners as appropriate, and support other manufacturing and engineering projects as needed.
Ideal Background and Qualifications
  • Bachelor’s degree in Chemical Engineering from an accredited institution.
  • Minimum of seven (7) years of progressive engineering experience in chemical manufacturing, process engineering, or manufacturing engineering.
  • Demonstrated hands-on experience supporting, troubleshooting, modifying, or scaling high-pressure reactor systems, pressure vessels, or comparable high-pressure chemical processing equipment is required. Candidates without experience in high-pressure processing will not be considered.
  • Experience scaling chemical processes from laboratory or pilot operations into commercial manufacturing.
  • Experience leading capital equipment and process improvement projects.
  • Experience working within an ISO 13485, ISO 9001, GMP, FDA-regulated, or similarly regulated manufacturing environment preferred.
Knowledge, Skills & Abilities
  • Strong knowledge of high-pressure processing equipment, pressure vessels, batch manufacturing, chemical reaction engineering, and process scale-up.
  • Understanding of heat transfer, mixing technology, process instrumentation, process safety, and equipment reliability.
  • Experience with PFDs, P&IDs, validation activities (IQ/OQ/PQ), engineering change management, and process risk assessment.
  • Process Hazard Analysis and Failure Modes Effects Analysis experience
  • Statistical process analysis for multifactor Design of Experiments experience
  • Free radical polymerization reaction experience
  • System configuration and process design (P&ID) experience
  • Process and Product Design Experience
  • Strong project management, analytical, troubleshooting, and problem-solving skills.
  • Excellent written and verbal communication skills with the ability to collaborate effectively across all levels of the organization.
  • Hands-on approach with the ability to balance technical leadership and day-to-day engineering support.
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