Sr. Process Engineer

We are seeking a talented Chemical Engineer who will serve as a subject matter expert in plant unit operations including reactions, separations, distillations, heat transfer, solids handling, and specialty formulation processes. The ideal candidate will identify, develop, and implement process improvements to enhance safety, yield, efficiency, throughput, and reliability. This role involves leading or supporting process hazard analyses, troubleshooting plant issues, and providing technical support to operations and maintenance teams.

Responsibilities

• Serve as subject matter expert for plant unit operations including reactions, separations, distillations, heat transfer, solids handling, and specialty formulation processes.
• Identify, develop, and implement process improvements to increase safety, yield, efficiency, throughput, and reliability.
• Lead or support process hazard analyses (PHAs), HAZOP studies, and other risk assessments.
• Troubleshoot plant issues and provide hands-on technical support to operations and maintenance teams.
• Develop and maintain process flow diagrams (PFDs) and piping and instrumentation diagrams (P&IDs).
• Support technology transfers, scale-up, and new product introductions.
• Manage the full life cycle of capital projects (CapEx) from concept through commissioning, including scope definition, budgeting, engineering design, procurement, installation, and start-up.
• Collaborate with cross-functional teams to ensure project alignment with business goals and compliance requirements.
• Coordinate external engineering firms, contractors, and vendors to ensure timely and on-budget project execution.
• Prepare and present project justifications, risk analyses, and status updates to leadership.
• Drive a zero-incident safety culture through design, behavior, and leadership.
• Ensure all process designs and modifications meet regulatory, environmental, and safety standards.
• Maintain compliance with internal standards and industry best practices.
• Oversee installation and startup of new systems, ensuring alignment with process requirements and safety protocols.
• Lead cross-functional teams to deliver projects on time and within budget.

• Bachelor’s or Master’s degree in Chemical Engineering.
• 10 years of experience in process and project engineering within specialty chemicals, pharmaceuticals, or fine chemicals.
• Strong understanding of chemical unit operations: distillation, reaction engineering, liquid-liquid extraction, heat/mass transfer.
• Proficiency in simulation tools and hydraulic modeling software.
• Excellent communication and leadership skills.
• Proven track record in managing capital projects ($250k–$5M range), from FEL through commissioning.
• Experience with batch processing environments.
• Regulatory compliance (OSHA, EPA).
• Experience with automation systems and process control (PLC).

• Six Sigma, Lean Manufacturing, or PMP certification is a plus.
• Ability to thrive in a fast-paced, dynamic environment with shifting priorities.
• Strong experience in detail design evaluation for layout, operational workflow, code compliance.
• Experience in assessment of contractor design details for code compliance, dimensional compliance, and review for integration into overall project workflow and design.
• Ability to navigate projects that improve the overall manufacturing environment.
• Proficiency in AUTOCAD, MS Project, and Excel for design computational analysis.
• Familiarity with safety system design, OSHA PSM elements, and hazard analysis methods.
• Excellent analytical and math skills.
• Proficient in continuous improvement.
• Strong written and verbal communication skills.
• Ability to persuade others to change existing practices.
• Strong attention to detail.
• Proven ability to identify, assess, and solve problems.
• Knowledge of process engineering software systems.

The role is based in a manufacturing and distillation/reactor laboratory environment. The company boasts an excellent culture with an expanding growth trajectory. Highlights include monthly visits from an ice cream ambulance, volunteering opportunities with CTfood bank, company picnics, outings with Danbury firefighters, an engagement committee, HR newsletter and wellness challenges, and a promotion program. Relocation assistance is also offered.

Job Type & Location

This is a Permanent position based out of Danbury, Connecticut.

Pay and Benefits

The pay range for this position is $100000.00 - $157000.00/yr.

10 days vacation
7 days sick
10 Holidays (last week of year shut down paid)
Medical, Dental, Vision, 401k & profit sharing, tuition reimbursement
Annual raise and bonus

Workplace Type

This is a fully onsite position in Danbury,CT.

Application Deadline

This position is anticipated to close on Nov 4, 2025.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 30,000 consultants and more than 4,500 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing due to a disability, please email actalentaccommodation@actalentservices.com for other accommodation options.

Salary : $100,000 - $157,000