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Senior Process Development Engineer Jobs in Rochester, NY

American Packaging Corporation

Senior Process Engineer

NY · On-site

$105K - $135K/yr

This involves observing trials/developmental orders and production runs, and communicating with ... Lead Process Engineer meetings, schedule meetings, take notes for actions, and follow up with other ...

Crosby Brownlie Inc.

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Senior Process Piping Engineer / Designer / Project Manager

Rochester, NY · On-site

$110K - $150K/yr

Senior Process Piping Engineer / Designer / Project Manager (Food, Beverage & Pharma) Location: Rochester, NY and Central NY (In-Person) Department: Engineering & Project Delivery Reports To: VP ...

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Senior Process Development Engineer information

See Rochester, NY salary details

$74K

$119.6K

$168.3K

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

As of May 30, 2026, the average yearly pay for senior process development engineer in Rochester, NY is $119,556.00, according to ZipRecruiter salary data. Most workers in this role earn between $102,700.00 and $132,800.00 per year, depending on experience, location, and employer.

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 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 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 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 Rochester, NY are hiring for Senior Process Development Engineer jobs? Cities near Rochester, NY 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 Rochester, NY as of May 2026, with employment types broken down into 83% Full Time, 13% Part Time, and 4% Contract. Highlights an 93% Physical, 2% Hybrid, and 5% Remote job distribution, with an average salary of $119,556 per year, or $57.5 per hour.
Process Engineer

Process Engineer

Graham Personnel Services

Rochester, NY

Full-time

Posted 5 days ago

Job description

Process Development Engineer – Solar
Summary
The Process Development Engineer is responsible for developing, implementing, and optimizing thin-film coating processes to support stable, high-volume production of photovoltaic (solar) modules.
Reporting Structure
Reports to: VP, Manufacturing
Location
Rochester, NY area
Key Responsibilities
Product R&D
  • Design and execute experiments to develop and improve materials and manufacturing processes for enhanced product performance
  • Conduct lab and pilot-scale testing; analyze results and recommend next steps
  • Monitor product and process performance throughout development cycles
  • Evaluate data and identify continuous improvement opportunities
  • Perform material characterization using tools such as SEM, AFM, XRF, and profilometry
  • Support implementation of in-line metrology tools to ensure coating quality and consistency
Manufacturing Development
  • Optimize processes for high-volume, stable production environments
  • Develop and maintain process documentation and SOPs
  • Define equipment requirements and assist with vendor selection
  • Support production cost estimation and process efficiency improvements
  • Ensure compliance with environmental, health, and safety regulations
  • Assist with production line layout and scale-up activities
Required Qualifications
  • Experience developing thin-film products and manufacturing processes
  • Knowledge of roll-to-roll processing (unwinding/winding, splicing, coating, laminating, web handling)
  • Exposure to manufacturing or production environments
  • Experience with at least one of the following:
    • Gravure coating
    • Slot die coating
    • Flexographic printing
    • Laser patterning
Preferred Qualifications
  • Experience with thin-film solar technologies (e.g., perovskite solar cells)
  • Ink formulation experience
  • Design of Experiments (DOE)
  • Vacuum deposition or atomic layer deposition
  • Lean manufacturing knowledge
  • Project management experience
Education & Experience
  • Bachelor’s degree in Engineering, Science, or related technical field (advanced degree preferred)
  • Experience supporting production environments
  • Experience with process or product scale-up
Core Competencies
  • Strong technical and analytical problem-solving skills
  • Ability to collaborate across teams and with external partners
  • Familiarity with process simulation tools and standard operating procedures
  • Experience with CAD/AutoCAD preferred
  • Understanding of health and safety regulations
Physical Requirements
  • Ability to bend, twist, push, and pull as needed
  • Ability to lift up to 40 lbs
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