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Sr Process Engineer Jobs in Boerne, TX (NOW HIRING)

Xpel

Senior Process Engineer

San Antonio, TX · On-site

$93K - $121K/yr

We are seeking a highly skilled Process Engineer with direct experience in thermoplastic polyurethane (TPU) extrusion for Paint Protection Film (PPF) applications. This role is responsible for ...

XPEL, Inc.

Senior Process Engineer

San Antonio, TX · On-site

$93K - $121K/yr

We are seeking a highly skilled Process Engineer with direct experience in thermoplastic polyurethane (TPU) extrusion for Paint Protection Film (PPF) applications. This role is responsible for ...

ECONTROLS LLC

Senior Process Engineer

San Antonio, TX · On-site

$93K - $121K/yr

We are looking for a Process Engineer with 5-10 years or more years of manufacturing industry experience, ideally with time spent working in one or more engineering discipline. (Mechanical ...

Vestal Corporation

Process Engineer, Senior

San Antonio, TX · On-site

$95K - $123K/yr

The Senior Process Engineer is responsible for the design, engineering, and implementation of designs for process/ chemical systems within industrial facilities. JOB DUTIES: * Proficient in designing ...

Vestal Corporation

Process Engineer, Senior

San Antonio, TX · On-site

$125K - $165K/yr

The Senior Process Engineer is responsible for the design, engineering, and implementation of designs for process/ chemical systems within industrial facilities. JOB DUTIES: * Proficient in designing ...

Vestal Corporation

Process Engineer, Senior

San Antonio, TX · On-site

$95K - $123K/yr

The Senior Process Engineer is responsible for the design, engineering, and implementation of designs for process/ chemical systems within industrial facilities. JOB DUTIES: * Proficient in designing ...

Cross Resource Group

Process Engineer

San Antonio, TX

$30 - $39/hr

Process Engineer Position Summary The Process Engineer will provide additional engineering and operational support for ongoing chemical pilot plant projects in a contract capacity. This position ...

Humetis Group

Process Engineer

San Antonio, TX · On-site

Job Title: Process Engineer Reports To: Engineering Manager Location: San Antonio, TX Position Summary The Process Engineer is a key contributor to the success of client'sfood manufacturing ...

medplast

Process Engineer

San Antonio, TX · On-site

The Corporate Process Engineer is responsible for leading advanced process development across the full lifecycle of molding and manufacturing programs, applying expert scientific molding and cavity ...

medplast

Process Engineer

San Antonio, TX · On-site

The Corporate Process Engineer is responsible for leading advanced process development across the full lifecycle of molding and manufacturing programs, applying expert scientific molding and cavity ...

XPEL, Inc.

Process Engineer

San Antonio, TX · On-site

The Process Engineer supports the development, optimization, and scale-up of manufacturing processes across production and supply chain operations. This role applies engineering expertise to drive ...

Aspen Enterprises LTD

Process Engineer

San Antonio, TX · On-site

Process Engineer DEPARTMENT: Engineering REPORTS TO: Director of Engineering LOCATION: San Antonio, TX HOURS / SHIFT: 1st Shift BENEFITS & PERKS: Finlays Solutions is committed to supporting the ...

Xpel

Process Engineer

San Antonio, TX · On-site

The Process Engineer supports the development, optimization, and scale-up of manufacturing processes across production and supply chain operations. This role applies engineering expertise to drive ...

medplast

Process Engineer

San Antonio, TX · On-site

The Corporate Process Engineer is responsible for leading advanced process development across the full lifecycle of molding and manufacturing programs, applying expert scientific molding and cavity ...

Viant

Process Engineer

San Antonio, TX · On-site

The Corporate Process Engineer is responsible for leading advanced process development across the full lifecycle of molding and manufacturing programs, applying expert scientific molding and cavity ...

Actalent

Process Engineer (ME)

San Antonio, TX

Process Engineer (Mechanical Emphasis) This entry-level Process Engineer role focuses on supporting a petroleum pilot plant from concept through operation. The engineer processes data compilations ...

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All JobsSr Process Engineer JobsSr Process Engineer Jobs in Boerne, TX

Sr Process Engineer information

See Boerne, TX salary details

$70.5K

$113.8K

$160.2K

How much do sr process engineer jobs pay per year?

As of Sep 2, 2026, the average yearly pay for sr process engineer in Boerne, TX is $113,799.00, according to ZipRecruiter salary data. Most workers in this role earn between $97,700.00 and $126,400.00 per year, depending on experience, location, and employer.

What is a Sr Process Engineer?

Senior Process Engineers are experienced professionals responsible for designing, optimizing, and overseeing the processes used in manufacturing or production environments. They analyze workflows, troubleshoot process issues, and implement improvements to increase efficiency, reduce costs, and ensure product quality. Sr Process Engineers often lead teams, manage projects, and work closely with other departments such as quality assurance, maintenance, and operations. Their expertise is crucial in industries like chemicals, pharmaceuticals, oil and gas, and food processing. They typically hold a degree in engineering and have several years of experience in process engineering roles.

What are the key skills and qualifications needed to thrive as a Sr Process Engineer?

To thrive as a Sr Process Engineer, you need a solid background in chemical, mechanical, or industrial engineering, often with a bachelor's or master's degree and relevant industry experience. Familiarity with process simulation software (such as Aspen Plus or HYSYS), Six Sigma or Lean certifications, and knowledge of safety and regulatory standards are typically required. Strong problem-solving, project management, and communication skills help distinguish top performers in this role. These skills and qualifications are vital for optimizing processes, ensuring efficiency and safety, and driving continuous improvement in complex manufacturing environments.

How does a Sr Process Engineer typically collaborate with cross-functional teams to improve manufacturing efficiency?

Sr Process Engineers work closely with teams such as production, quality assurance, maintenance, and R&D to identify areas for process optimization. They often lead or participate in cross-functional meetings to gather data, analyze workflow bottlenecks, and implement solutions that enhance efficiency and product quality. Effective communication and project management skills are essential, as Sr Process Engineers must balance technical requirements with practical constraints while ensuring all stakeholders are aligned with proposed changes.

What is the difference between Sr Process Engineer vs Process Engineer?

AspectSr Process EngineerProcess Engineer
QualificationsBachelor's degree in engineering, 5+ years experience, certifications like Six SigmaBachelor's degree in engineering or related field, 1-3 years experience
ResponsibilitiesLead process improvements, optimize manufacturing processes, mentor junior staffAssist in process development, data collection, support process optimization
Work EnvironmentManufacturing plants, industrial facilities, cross-functional teamsManufacturing settings, engineering teams, project-based tasks

The main difference between a Sr Process Engineer and a Process Engineer lies in experience, responsibility level, and scope of work. The Sr Process Engineer typically leads projects, mentors others, and has more advanced qualifications, while the Process Engineer supports and executes process improvements under supervision.

How much does a senior process engineer earn?

A senior process engineer typically earns between $80,000 and $130,000 annually, depending on experience, industry, and location. They often have specialized skills in process optimization, project management, and may hold certifications such as Six Sigma or PMP.

What does a senior process engineer do?

A senior process engineer designs, develops, and optimizes manufacturing or industrial processes to improve efficiency, safety, and quality. They analyze data, troubleshoot issues, and implement process improvements, often using tools like process simulation software and adhering to industry standards. They also mentor junior engineers and collaborate with cross-functional teams to ensure smooth operations.

What are popular job titles related to Sr Process Engineer jobs in Boerne, TX?

For Sr Process Engineer jobs in Boerne, TX, the most frequently searched job titles are:

What cities near Boerne, TX are hiring for Sr Process Engineer jobs?

Cities near Boerne, TX with the most Sr Process Engineer job openings:

Sr Process Engineer jobs near you
Infographic showing various Sr Process Engineer job openings in Boerne, TX as of August 2026, with employment types broken down into 1% As Needed, 78% Full Time, 18% Part Time, 2% Contract, and 1% Nights. Highlights an 89% Physical, 3% Hybrid, and 8% Remote job distribution, with an average salary of $113,799 per year, or $54.7 per hour.

Senior Process Engineer

Xpel

San Antonio, TX • On-site

$93K - $121K/yr

Full-time

Re-posted 2 days ago

Job description

Job Summary:

We are seeking a highly skilled Process Engineer with direct experience in thermoplastic polyurethane (TPU) extrusion for Paint Protection Film (PPF) applications. This role is responsible for working with organizations developing, optimizing, and scaling extrusion processes that produce optical-grade TPU films with exceptional clarity, mechanical durability, and surface performance. The ideal candidate understands the unique challenges of PPF manufacturing, including optical defects, gel control, surface uniformity, and tight thickness tolerances.

Core Duties

Process Development and Optimization

  • Develop, refine, and optimize TPU extrusion processes in collaboration with existing organizations in internal lab-based development
  • Establish and maintain process parameters to ensure consistent product quality
  • Lead root-cause analysis and corrective actions for process deviations, scrap, and downtime.
  • Implement continuous improvement initiatives using Lean, Six Sigma, or similar methodologies.

Technical Leadership, Support, and Troubleshooting

  • Provide day-to-day technical support to production teams for extrusion lines.
  • Troubleshoot issues related to melt temperature, die design, screw configuration, cooling, and downstream equipment.
  • Partner with R&D to scale up new TPU formulations and product designs from lab to production.
  • Conduct extrusion trials, document results, and establish robust manufacturing processes.
  • Collaborate with research and development teams as technologies transition to pilot & scale-up environments to ensure successful commercialization.

Quality, Safety, and Compliance Leadership

  • Develop and maintain process documentation, including work instructions, control plans, and standard operating procedures.
  • Work closely with Quality to ensure compliance with customer specifications and industry standards.
  • Analyze process data to identify trends and drive quality improvements.

Data Performance, Analytics, and Strategic Improvement

  • Monitor key process indicators (KPIs) such as yield, scrap rate, cycle time, and line efficiency.
  • Use statistical tools to evaluate process capability and stability.
  • Recommend and implement process automation or digital monitoring enhancements.

Basic Qualifications

  • Bachelor's degree in Chemical, Polymer, Mechanical, Materials Engineering, or a related field.
  • 6+ years of progressive experience in process engineering, with strong exposure to polymer films, coatings, or similar manufacturing environments.
  • Deep hands-on expertise with manufacturing equipment, including leading equipment optimization, upgrades, and reliability improvements.
  • Proven ability to lead complex troubleshooting efforts, applying data-driven methodologies to resolve issues and optimize critical process parameters.
  • Advanced proficiency in continuous improvement and problem-solving frameworks with demonstrated project leadership and measurable results.
  • Strong analytical capabilities with experience in statistical analysis, process capability, and hypothesis-driven problem solving.
  • Demonstrated leadership in cross-functional collaboration, with the ability to influence stakeholders and drive alignment across production, quality, and R&D teams.
  • Experience managing multiple high-impact projects simultaneously in fast-paced manufacturing environments, with strong prioritization and execution skills.
  • Strategic mindset with a strong attention to detail, focused on long-term process sustainability, scalability, and cost optimization.
  • Proven track record of mentoring junior engineers and contributing to team development and technical growth.
  • Willingness and ability to travel 25-50% to support multi-site operations, equipment vendors, and scale-up activities.

XPEL is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.

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About XPEL

Sourced by ZipRecruiter

Industry

Motor vehicle parts manufacturing

Company size

201 - 500 Employees

Headquarters location

San Antonio, TX, US

Social media

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