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Senior Process Development Engineer Jobs in Washington, DC

Responsibilities We are seeking a Senior Process Engineer to provide enterprise-focused engineering ... methodology development and evaluation, process engineering across all phases of acquisition ...

Responsibilities We are seeking a Senior Process Engineer to provide enterprise-focused engineering ... methodology development and evaluation, process engineering across all phases of acquisition ...

Responsibilities We are seeking a Senior Process Engineer to provide enterprise-focused engineering ... methodology development and evaluation, process engineering across all phases of acquisition ...

As a Development Support Process Engineer on our team, you will support a customer Program Management Office (PMO) overseeing a large multi-organizational agile software development project. You will ...

As a Development Support Process Engineer on our team, you will support a customer Program Management Office (PMO) overseeing a large multi-organizational agile software development project. You will ...

As a Development Support Process Engineer on our team, you will support a customer Program Management Office (PMO) overseeing a large multi-organizational agile software development project. You will ...

ERG is seeking a Senior Process Safety Engineer or Chemical Engineer to join our Risk Management Program (RMP) and Process Safety Management (PSM) compliance and enforcement team providing support to ...

ERG is seeking a Senior Process Safety Engineer or Chemical Engineer to join our Risk Management Program (RMP) and Process Safety Management (PSM) compliance and enforcement team providing support to ...

ERG is seeking a Senior Process Safety Engineer or Chemical Engineer to join our Risk Management Program (RMP) and Process Safety Management (PSM) compliance and enforcement team providing support to ...

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Senior Process Development Engineer information

See Washington, DC salary details

$84.9K

$137.1K

$193K

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

As of Jun 25, 2026, the average yearly pay for senior process development engineer in Washington, DC is $137,125.00, according to ZipRecruiter salary data. Most workers in this role earn between $117,700.00 and $152,300.00 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.

Do R&D engineers make good money?

Senior Process Development Engineers typically earn competitive salaries that reflect their specialized skills in process optimization, research, and development. Compensation varies by industry, location, and experience, but they generally earn above-average wages compared to many other engineering roles. Advanced knowledge of tools like statistical analysis and process modeling can also influence earning potential.

Is 40 too late to be an engineer?

Age is not a barrier to becoming a senior process development engineer or any engineering role. Many engineers start or transition into the field later in life, and success depends on skills, experience, and continuous learning, such as gaining relevant certifications or technical expertise. Employers value diverse backgrounds and practical knowledge regardless of age.

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 engineer makes $500,000 a year?

Senior Process Development Engineers in specialized industries such as semiconductor manufacturing or pharmaceuticals can earn $500,000 or more annually, especially with extensive experience, advanced skills, and leadership roles. High compensation often includes bonuses, stock options, or profit sharing, and requires expertise in process optimization, automation tools, and industry certifications.

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 Washington, DC? For Senior Process Development Engineer jobs in Washington, DC, the most frequently searched job titles are:
What job categories do people searching Senior Process Development Engineer jobs in Washington, DC look for? The top searched job categories for Senior Process Development Engineer jobs in Washington, DC are:

Senior Associate, Process Development

Kolon TissueGene, Inc.

Rockville, MD • On-site

Other

Retirement, PTO

Posted 12 days ago


Job description

ABOUT KOLON TISSUEGENE

Kolon TissueGene, Inc. (KTG) is a clinical-stage biopharmaceutical company developing TG-C, a first-in-class cell and gene therapy for osteoarthritis — a disease with significant unmet need and no approved disease-modifying treatment in the U.S. We are a small, high-conviction team preparing for our most pivotal chapter: commercial launch. Every person we hire shapes how we get there.


ABOUT THE ROLE

The Senior Process Development Associate will independently design, execute, and document process development studies that support our clinical manufacturing programs. This role requires hands-on laboratory experience and the ability to plan, execute, analyze, and document PD activities with minimal supervision.


This is not a manufacturing technician role, and it is not an entry-level PD position. We're looking for someone who can run projects independently and contribute meaningfully to protocol development, batch records, and process optimization — bringing both technical depth and ownership to everything they do.


WHAT YOU WILL DO

  • Independently design and execute process development studies, including experimental plans, study protocols, and batch records
  • Perform and oversee scale-up or scale-out studies, process optimization runs, and special/non-routine PD runs
  • Analyze and interpret experimental data with scientific rigor
  • Review results, troubleshoot issues, and recommend process improvements to enhance robustness and efficiency
  • Contribute to documentation packages with accuracy and attention to detail
  • Collaborate cross-functionally with Manufacturing, Analytical Development, and Research; maintain compliance with GMP expectations where applicable


WHAT WE ARE LOOKING FOR

REQUIRED

  • Bachelor’s degree required, with a strong preference for a STEM field; laboratory coursework and hands-on lab training required.
  • 3–5 years of relevant Process Development or closely related experience — this role requires independent PD capability, not entry-level lab support.
  • Demonstrated experience independently designing PD studies, executing experiments, and reviewing and interpreting data.
  • Strong hands-on laboratory experience with a solid grounding in cell culture techniques and core PD laboratory methods.
  • Upstream processing experience required.
  • Experience generating and maintaining technical documentation (experimental plans, protocols, batch records, reports).

PREFERRED

  • GMP manufacturing exposure.
  • Biologics experience.
  • Cell therapy or gene therapy experience (preferred but not mandatory).
  • Downstream processing experience — a strong plus.
  • Broader exposure beyond a single modality.


WHY KTG

First-in-Class Science TG-C is a cell and gene therapy advancing toward U.S. commercialization for osteoarthritis — a disease with no approved disease-modifying treatment. Your work in the lab directly supports a potential paradigm shift in how this condition is treated.

Real Ownership You will run your own studies end-to-end — from experimental design through documentation — with the autonomy that comes from being trusted to deliver.

Direct Access to Leadership On a small, mission-driven team, you will work closely with PD leadership, Manufacturing, Analytical Development, and Research — with no layers between your work and the program's direction.

Culture of Rigor & Curiosity We value deep scientific thinking, intellectual honesty, and continuous improvement, and we invest in the tools and training to help you grow your expertise.


BENEFITS

  • Onsite yet flexible work schedules
  • Premium-free global health insurance (50% dependent coverage)
  • 401k with immediate eligibility
  • Long-term incentive bonuses
  • On-site gym & wellness perks
  • Extra PTO accrual every year
  • Global and local training opportunities


WORK ENVIRONMENT

This is a full-time, onsite role based at our Rockville, MD headquarters. Work is performed in a general and biological laboratory environment; proper gowning and PPE (lab coat, safety glasses, gloves, hair and shoe covers) are required where applicable.


PHYSICAL REQUIREMENTS

Ability to sit for extended periods at a computer workstation.

Extensive keyboarding involving repetitive finger motion.

Ability to communicate via telephone and video conference.

Ability to lift, push, or carry up to 25 lbs occasionally.


DISABILITY ACCOMMODATION & VETERAN SELF-IDENTIFICATION

We invite all applicants to voluntarily self-identify as a person with a disability and/or a protected veteran. This information is collected for federal compliance purposes only and will not affect hiring decisions. To request a reasonable accommodation at any stage of the application or interview process, contact us at hr@tissuegene.com. All requests are handled confidentially and in accordance with applicable law.


Kolon TissueGene, Inc. is an equal opportunity employer.

We celebrate diversity and are committed to creating an inclusive environment for all employees. All qualified applicants will receive consideration without regard to race, color, religion, gender, identity, sexual orientation, national origin, disability, or veteran status.