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Senior Process Development Engineer Jobs in Raleigh, NC

Polyzen LLC

Extrusion Development Engineer

Apex, NC · On-site

Our range of materials and processing technologies allow us to provide optimum solutions for ... The Extrusion Development Engineer is responsible for driving extrusion development projects ...

DivIHN

Process Engineer Pharmaceuticals I

NC · On-site

Process Engineer Pharmaceuticals I Duration: 7+ Months Location: Research Triangle Park, NC Only W2 ... Support process development and experimental studies, including process characterization and ...

Align Technology

Sr. R&D Engineer, New Products

Raleigh, NC · On-site

$101K - $139K/yr

Sr. R&D Engineer, New Products Department: Research & Development Employment Type: Full Time Location: US-North Carolina-Raleigh Description We are seeking a Sr. R&D Engineer, New Products to lead ...

New

CommScope, Inc.

Junior R&D Engineer

Apex, NC · On-site

Present findings and design recommendations to senior engineering and program stakeholders ... Drive innovative material, design, or process solutions to meet stringent OSP reliability ...

Freudenberg

Product Development Engineer

Durham, NC

Develop and optimize raw materials, processes, and products to support business objectives ... Engineering * Minimum of 5 years of experience in R&D, product development, or a similar technical ...

Marmon

Product Development Engineer

Holly Springs, NC · Hybrid

$100K - $135K/yr

Strong background in CAD, design analysis, DFMEA, DVP&R, and related processes. * Proven problem ... Collaborate closely with cross-functional teams in engineering, product development, quality ...

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All JobsSenior Process Development Engineer JobsSenior Process Development Engineer Jobs in Raleigh, NC

Senior Process Development Engineer information

See Raleigh, NC salary details

$72.9K

$117.7K

$165.7K

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

As of Jun 10, 2026, the average yearly pay for senior process development engineer in Raleigh, NC is $117,735.00, according to ZipRecruiter salary data. Most workers in this role earn between $101,100.00 and $130,700.00 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, and why are they important?

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 engineers make $300,000 a year?

Senior Process Development Engineers in specialized industries such as semiconductor manufacturing, aerospace, or pharmaceuticals can earn $300,000 or more annually, especially with extensive experience, advanced skills, and relevant certifications. High compensation often reflects leadership roles, complex project management, or working in high-demand sectors with competitive salaries.
What are popular job titles related to Senior Process Development Engineer jobs in Raleigh, NC? For Senior Process Development Engineer jobs in Raleigh, NC, the most frequently searched job titles are:
What job categories do people searching Senior Process Development Engineer jobs in Raleigh, NC look for? The top searched job categories for Senior Process Development Engineer jobs in Raleigh, NC are:
Senior Process Development Engineer jobs near you
Extrusion Development Engineer

Extrusion Development Engineer

Polyzen LLC

Apex, NC • On-site

Full-time

Medical, Retirement, PTO

Posted 7 days ago

Job description

Who we are:
Polyzen is a leading developer and manufacturer of customized polymer-based materials, films, components, and assemblies for the medical device industry. Our range of materials and processing technologies allow us to provide optimum solutions for innovation-driven companies, ranging from entrepreneurial start-ups to major medical device manufacturers. From prototype development through full-scale production, we take pride in our quality, technical expertise, and customer service, and we strive to provide the best value throughout the product life cycle.
1st shift Monday-Friday 8:00 am-5:00 pm
About the role:
The Extrusion Development Engineer is responsible for driving extrusion development projects through the product life cycle by aiding in the development, validation, and commercialization of extruded films on machines such as Flat Die Extruders, Layflat Extrusion, and Laminators. This role will engage with key internal operational stakeholders and grow their business acumen by working with our business development teams, vendors, and clients. This role is a key contributor to the Solesis organization in achieving company metrics: on-time delivery, revenue, quality, and safety.
What you will do:
  • Leads multiple projects for extrusion development in various stages of the product lifecycle in line with agreed commitments to respective clients.
  • Designs manufacturing processes that are scalable to a production environment based on customer design and volume requirements.
  • Specifies tooling, fixtures, and equipment for the extrusion development process at the required scale and manufacturing throughput.
  • Develops and qualifies appropriate test and inspection methods for key product attributes.
  • Troubleshoot and complete general maintenance of extrusion equipment.
  • Ability to assemble and disassemble extruders for cleaning and/or job changes that require different tooling with a new setup.
  • Follow all Good Manufacturing Practices (GMP) and Good Documentation Practices (GDP) when completing daily tasks.
  • Partner cross-functionally with Quality and Engineering Leadership to drive development through the stage gate process.
  • Partner with Quality to ensure manufacturing teams are maintaining product adherence that complies with ISO 13485 and 9001 regulations, Good Manufacturing Practices (GMP), Good Documentation Practices (GDP), and all safety requirements.
  • Support the Quality team with any CAPA-related activity to complete root cause analysis and improve overall quality and performance of the products being manufactured for customers.
  • Comply with and follow all Standard Operating Procedures (SOPs) and ensure all quality documentation is completed correctly.
  • Train junior-level extrusion engineers or operators and act as the subject matter expert (SME) for all things extrusion engineering.

Who you are:
  • Bachelor's degree in business, operations management, engineering, or a similar related field preferred.
  • Minimum of five (5) to seven (7) years of experience in extrusion, blow molding, or injection molding operations.
  • Knowledge of machine operations that pertain to various polymers and extrusion.
  • Possess knowledge of ISO 13485, 9001, and GMP practices or possess the ability to understand and enforce the practices.
  • Ability to follow and make recommendations and changes to Work Instructions (WIs) and Standard Operating Procedures (SOPs).
  • Experience with manufacturing process development, qualifications, and capability assessment.
  • Ability to understand the client's needs, how the needs relate to the scope of the project, and how changes will affect other systems.
  • Ability to translate client inputs into engineering requirements based on technical skill set.
  • Ability to explain technical concepts to internal and external project stakeholders, including process capabilities, limitations, and areas for improvement.
  • Ability to prioritize and delegate tasks as appropriate to meet project objectives.
  • Ability to mentor junior-level engineers.
  • Excellent interpersonal skills with proven ability to get along well with others and work in a team environment.
  • Good presentation skills and the ability to present on a one-to-one basis and to small groups.

Perks / Benefits:
  • Generous Paid Time Off
  • Paid Breaks
  • Annual Bonuses
  • 401k with excellent company match
  • Health Insurance with multiple plans to choose from
  • Paid Short Term and Long Term Disability

Equal Opportunity Employer
This employer is required to notify all applicants of their rights pursuant to federal employment laws.
For further information, please review the Know Your Rights notice from the Department of Labor.

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