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Senior Process Development Engineer information

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$75K

$121.1K

$170.5K

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

As of Jun 9, 2026, the average yearly pay for senior process development engineer in Wethersfield, CT is $121,091.00, according to ZipRecruiter salary data. Most workers in this role earn between $104,000.00 and $134,500.00 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 Wethersfield, CT? For Senior Process Development Engineer jobs in Wethersfield, CT, the most frequently searched job titles are:
What cities near Wethersfield, CT are hiring for Senior Process Development Engineer jobs? Cities near Wethersfield, CT 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 Wethersfield, CT as of May 2026, with employment types broken down into 94% Full Time, and 6% Part Time. Highlights an 83% In-person, 6% Hybrid, and 11% Remote job distribution, with an average salary of $121,091 per year, or $58.2 per hour.
Director, Formulation and Process Development

Director, Formulation and Process Development

Alexion Pharmaceuticals

New Haven, CT • On-site

$175K - $263K/yr

Full-time

Medical, Dental, Vision, Retirement, PTO

Posted 11 days ago

Job description

You will lead and direct the formulation and process development of patient-centered injectable drug products. These products are for Alexion's diverse portfolio, which spans synthetic, peptide, genomic medicine, and protein-based modalities in multiple formats, including liquid, lyophilized, vial, prefilled, and cartridge-based presentations. You will also lead life cycle development opportunities, provide expertise in technology transfer and drug product engineering and technology development with internal and external partnerships. You will also ensure the development of portfolio projects in a phase-appropriate manner while managing the budget and interface partners. You will be a member of the Injectable Drug Product Management team and will need to collaborate and network with other departments within Product Development and Clinical Supplies (PDCS). Additionally, it will need to collaborate and network with Alexion Operations, Clinical Development, Quality, and Regulatory organizations.
You Will:
  • Formulation and process development and manufacturing of patient-centered, unique injectable drug products for Alexion's diverse portfolio from pre-clinical to successful licensure.

  • Develop drug product development strategies through internal/external partnerships and product integration into drug/device combination products.

  • Enable the progression of Alexion's diverse portfolio that spans peptide, nucleic acid, protein-based modalities, as well as modalities for gene delivery as liquid and lyophilized dosage forms in vial, prefilled syringe, and cartridge-based presentations.

  • Ensure tech transfer of Alexion's portfolio with specialized input on engineering solutions for equipment and processes.

  • Review and develop drug product technology roadmap and manage important investments.

  • Mentor and develop colleagues in a matrix team for efficient and successful drug product development and manufacturing in a phase appropriate manner.

  • Partner with functions across Alexion to build the best strategies for developing products in Alexion's diverse portfolio.

  • Provide subject matter expertise for preparing regulatory filings, regulatory interactions including inspections, audits and is accountable for the technical content of the relevant drug product sections of regulatory submissions.

  • Work with the Head on the development on drug product development strategies within PDCS and with partners in Operations, Regulatory Affairs, and Commercial organizations.

You Have:
  • Must have a BS or equivalent in Bio/Chemical Engineering, Pharmaceutical Sciences, Biochemistry, or related discipline with relevant experience

  • At least 8 years of experience in managing a group of drug product development scientists or engineers with end to end drug product development experience (spanning formulation, process development, quality attribute assessment, tech transfer and manufacturing support) for mAbs, fusion proteins, injectable peptides/synthetics programs.

  • At least 5 years of experience managing a team of scientists and engineers at different levels (directly or in a matrix team) and ensuring their career growth.

  • Must be proficient in current approaches for formulation and drug product process development, manufacturing processes and equipment, regulatory expectations and applying these to developing efficient approaches to ensure product licensure.

  • Knowledge of high concentration protein formulation development, aseptic processes, vial, prefilled syringe, cartridge presentations, liquid and lyophilization dosage forms is important.

  • Knowledge of current regulatory guidelines and cGMP requirements is necessary

Benefits offered include:
  • A qualified retirement program [401(k) plan]

  • Paid vacation, holidays, and paid leaves

  • Health benefits including medical, prescription drug, dental, and vision coverage following the terms and conditions of the applicable plans.

Additional details of participation in these benefit plans will be provided if an employee receives an offer of employment. The annual base salary for this position ranges from $175,000 to $263,000. However, base pay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. In addition, our positions offer a short-term incentive bonus opportunity; eligibility to participate in our equity-based long-term incentive program (salaried roles), to receive a retirement contribution (hourly roles), and commission payment eligibility (sales roles).
#LI-Onsite #Alexion
Date Posted
29-May-2026
Closing Date
29-Jun-2026
Our mission is to build an inclusive environment where equal employment opportunities are available to all applicants and employees. In furtherance of that mission, we welcome and consider applications from all qualified candidates, regardless of their protected characteristics. If you have a disability or special need that requires accommodation, please complete the corresponding section in the application form.

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