Senior Process Engineer Jobs in Illinois (NOW HIRING)

The Senior Process Development Engineer is responsible for leading complex process research and development activities to enable the successful scale-up, optimization, and industrialization of new and existing products. The role focuses on developing robust manufacturing processes, applying scale-up laws, and building process models for existing or new unit operations. The position combines experimental work, process modeling and simulation, and technical leadership to support business objectives while ensuring compliance with safety, quality, and regulatory standards.

Key Responsibilities

Leadership and Direction

• Communicate and execute local action plans aligned with the function’s strategy and the broader organization’s mission and vision.
• Demonstrate strong leadership behaviors, including effective communication, accountability, and proactive problem solving.
• Provide technical leadership within process R&D programs and across cross-functional teams.

Process Research and Development

• Lead and manage significant elements of the organization’s process R&D program, with accountability for process development, scale-up, and technology transfer.
• Develop new manufacturing processes for new products, with a strong emphasis on process design, robustness, and scalability.
• Identify new process opportunities and conduct innovative experimental and modeling work to translate laboratory concepts into manufacturable solutions.

Process Experiments and Scale-Up

• Propose, design, prioritize, and safely execute laboratory, pilot-scale, and scale-up experiments.
• Apply fundamental engineering principles and scale-up laws to guide process design and scale-up decisions.
• Interpret experimental data and integrate scientific and engineering principles into process development projects.

Process Modeling, Data, and Analytics

• Develop and apply process models for existing and new unit operations using appropriate modeling, simulation, and statistical tools.
• Use data analysis, statistical methods, and modeling to evaluate hypotheses, predict performance, and optimize processes.
• Define and lead execution of data and analytics reporting strategies, ensuring results are communicated in a clear, actionable manner to stakeholders.

Methodologies, Tools, and Continuous Improvement

• Identify gaps or shortcomings in current process development methodologies, tools, and workflows.
• Propose, implement, and standardize improved process development, modeling, and scale-up practices.
• Develop and validate new test methods and process characterization techniques as required.

Communication and Collaboration

• Write clear technical reports documenting process development work, experimental results, and modeling outcomes.
• Present technical findings to R&D, operations, and management, and communicate effectively across functions and sites.
• Engage with external partners, suppliers, customers, and development collaborators as needed to support process development goals.

Innovation and Intellectual Property

• Contribute to innovation through the development of novel processes, unit operations, and modeling approaches.
• Understand intellectual property related to process and manufacturing technologies and support invention disclosures, patent analyses, and interactions with patent counsel.
• Maintain awareness of external technological advances and competitive process technologies.

Project and Portfolio Management

• Plan and deliver process development projects or workstreams using appropriate project management methodologies.
• Balance technical depth with project execution to ensure milestones are achieved on time and within scope.
• Act as a process R&D representative on strategic and cross-functional business teams.

People Development

• Provide technical guidance, coaching, and mentoring to junior engineers, scientists, and technicians.
• Support capability building within the team through training, knowledge sharing, and best-practice development.

Safety, Quality, and Compliance

• Comply with and actively support R&D and laboratory safety programs.
• Assume responsibility for assigned lab, pilot, or process areas, including safety, quality, and maintenance standards.

Required Skills and Competencies

• Advanced knowledge of process engineering principles, including scale-up laws and unit operations.
• Strong background in process modeling, simulation, and data analysis.
• Proficiency with analytical, statistical, and scientific software used for modeling and process development.
• Ability to manage complexity, optimize work processes, and apply continuous improvement principles.
• Strong communication, collaboration, and stakeholder management skills.

Education and Experience

• Bachelor’s degree in Chemical Engineering, Process Engineering, or a related engineering discipline (Master’s or PhD preferred).
• Typically 5+ years of experience in process R&D, scale-up, or manufacturing process development.
• Demonstrated experience in process modeling, simulation, and data-driven decision making.
• Experience mentoring or supervising junior engineers or technicians is preferred.

Additional information

Applicable only to applicants applying to a position in any location with a pay disclosure requirements under state or local law:

• The compensation range that is described below is the possible base pay compensation that the company believes in good faith that it will pay for this role at the time of posting based on job grade for the position. Individual compensation within this range is based on many factors such as years of experience etc. so the company might pay more or less than the posted range and it is understood that this range may be modified in the future.
• In addition to base compensation, MonoSol provides a yearly incentive compensation bonus, a profit sharing bonus when eligible, a comprehensive benefits package including medical, dental, vision insurances, short term disability, long term disability, accidental death and dismemberment, term life insurance, voluntary term life insurance, transit flexible spending account (if applicable), employee assistance program, identity theft protection, 401k and paid time off (vacation and sick days).

Compensation range - $102,994.61 - $169,225.50

Incentive Compensation Bonus Target – 10% - 15%

Paid time off amount – 15 days

CLOSING

The above statements are intended to describe the general nature and level of the work being performed by employees assigned to this position. This is not intended as an exhaustive list of all responsibilities, duties, and skills required. MonoSol, LLC reserves the right to make changes to the job description whenever necessary.

DISCLAIMER

As part of MonoSol, LLC’s employment process, finalist candidates will be required to complete a drug/alcohol test, physical, and background check prior to employment commencing. MonoSol, LLC is an equal opportunity employer. All qualified applicants will be considered without regard to race, national origin, gender, age, disability, sexual orientation, veteran status, or marital status.