Process Engineer, R&D

PDI; Woodcliff Lake (NJ); On-site; USD 105,000 - 120,000; Full time

Benefits offered by this job

Medical coverage

Dental & Vision

401(k) match

Life insurance

FSAs

Disability benefits

EAP

Tuition assistance

Paid parental leave

Job summary

PDI is seeking a Process Engineer, R&D to drive process development, scale-up, and commercialization from bench to full-scale manufacturing. You will bridge R&D, Operations, and partners, guiding pilot trials, DOE studies, and technology transfers while ensuring quality and cost standards.

Expect collaboration across packaging, formulation, QA, regulatory, and supply chain with limited travel. The role requires 4–8+ years in process development or NPI in consumer products or pharma, with a BS in

Qualifications

• Strong cross-functional collaboration and communication skills.
• Hands-on experience with DOE, SPC, PFMEA, and control plan development.
• Demonstrated success in leading factory trials and product launches.
• Lean/Six Sigma certification preferred.
• Ability to manage multiple priorities with urgency and accountability.

Responsibilities

• Translate product requirements and critical-to-quality attributes into scalable process parameters and control plans.
• Plan and execute bench, scale-up, and line validation trials, including DOE studies, to establish robust process windows and readiness for launch.
• Lead technology transfer from R&D to Manufacturing, including SOPs, equipment set-up, and operator training.
• Define and recommend the full manufacturing process - equipment, materials, process parameters, and controls - and issue formal, data-backed recommendations to Operations Engineering so scale-up, manufacturing line/asset selection, and CMO qualification decisions are validated before launch.

Skills

Cross-functional collaboration

DOE

PFMEA

Control plans

Line trials & launches

Lean Six Sigma

Multi-priority management

Education

BS in Chemical/Mechanical/Industrial Engineering

MS preferred

Job description

Description

POSITION PURPOSE

The Process Engineer, R&D leads process development, scale-up, and commercialization of new and redesigned products from bench through scale-up trials and into full-scale manufacturing, serving as the critical bridge between R&D, Operations, and external partners to ensure first-time-right launches. This role designs and executes bench and scale-up trials on production and partner assets, generates data to inform scale-up decisions, and establishes robust process windows for commercialization. As PDI builds internal pilot-scale capability, this role will define its requirements and lead pilot trials as a growing focus of the position. It also supports Procurement and Supply Chain in identifying, technically evaluating, and onboarding third-party manufacturers (CMOs/contract fillers/packagers), confirming they can meet PDI's quality, regulatory, and cost standards. Through strong collaboration with internal teams and external partners, this position ensures product launches are delivered safely, compliantly, on-time, and on-cost, while driving continuous improvement in process capability and efficiency.

ESSENTIAL FUNCTIONS AND BASIC DUTIES

• Translate product requirements and critical-to-quality attributes into scalable process parameters and control plans.
• Plan and execute bench, scale-up, and line validation trials, including DOE studies, to establish robust process windows and readiness for launch.
• Lead technology transfer from R&D to Manufacturing, including SOPs, equipment set-up, and operator training.
• Define and recommend the full manufacturing process - equipment, materials, process parameters, and controls - and issue formal, data-backed recommendations to Operations Engineering so scale-up, manufacturing line/asset selection, and CMO qualification decisions are validated before launch rather than resolved on the production floor.
• Partner with Packaging, Formulation, Quality, Regulatory, Supply Chain, and Operations to deliver first-time-right product launches.
• Partner with Procurement and Supply Chain to identify, evaluate, and qualify third-party manufacturers (CMOs, contract fillers/packagers), including technical capability assessments, pilot production readiness, and alignment with PDI's quality and regulatory standards.
• Assess, specify, and qualify new equipment, tooling, and raw materials required for scale-up and commercialization, ensuring alignment with manufacturing capability, automation opportunities, QMS, and EHS requirements.
• Lead PFMEA, DFM/DFR reviews, and process risk assessments, and own the DOE and process capability studies that drive first-pass yield, to ensure smooth commercialization and regulatory compliance.
• Track launch KPIs (e.g., yield, cycle time, scrap, OEE, COGS) and implement corrective actions as needed.
• Drive continuous improvement using Lean/Six Sigma tools to reduce cost and variability across processes.
• Maintain accurate, audit-ready technical documentation throughout the development and launch lifecycle.
• Champion safe work practices and ensure compliance with EHS requirements in laboratory and manufacturing environments, and in pilot plant environments as that capability is established.
• Participate in root cause investigations for process-related challenges.

PERFORMANCE MEASUREMENTS

• Bench-to-plant scaling accuracy within 10% of target process parameters.
• First-pass yield 95% within 30 days of launch.
• Provide validated process documentation and controls to support Manufacturing in achieving minimal scrap during launch and production startup
• OEE and throughput meet or exceed business case assumptions.
• On-time, in-full delivery of process documentation, SOPs, and control plans.
• Positive cross-functional feedback on collaboration and technical leadership.

EDUCATION/CERTIFICATION:

• BS in Chemical, Mechanical, Industrial, or related Engineering field required; MS preferred.

EXPERIENCE REQUIRED:

• 4-8+ years in process development, new product introduction, scale-up, or commercialization within consumer products, medical device, pharmaceutical, or related manufacturing; experience with liquid filling, nonwoven converting, or packaging operations preferred.

SKILLS/ABILITIES:

• Strong cross-functional collaboration and communication skills.
• Hands-on experience with DOE, SPC, PFMEA, and control plan development.
• Demonstrated success in leading factory trials and product launches.
• Lean/Six Sigma certification preferred.
• Ability to manage multiple priorities with urgency and accountability.

WORKING CONDITIONS:

• Office, laboratory, and manufacturing floor environments; pilot plant environments as that capability is established.
• Requires occasional lifting (<25 lbs.), standing for trials, and use of PPE.
• Limited travel (<15%) to manufacturing sites, suppliers, or external partners.

Applicants must be legally authorized to work in the United States without the need for current or future employer-sponsored visa sponsorship.

SALARY RANGE

• $105,000 - $120,000, plus bonus

PDI is pleased to offer a comprehensive and affordable benefits program to our associates, which includes:

• Medical & prescription drug coverage
• Dental / Vision plan
• 401(k) savings plan with company match
• Basic and supplemental life insurance
• Flexible Spending Accounts (FSAs)
• Short- and long-term disability benefits
• Health Advocacy Program / Employee Assistance Program (EAP)

Many other voluntary benefit plans and perks such as:

• Legal assistance
• critical illness
• hospital indemnity and accident coverage
• discounted home/auto/rental insurance
• employee discounts and pet insurance
• tuition assistance
• referral bonus program
• paid parental leave
• a health club rebate program and more

At PDI, we are also committed to helping our associates maintain a healthy and sustainable work/life balance and are proud to provide:

• Sick leave
• generous vacation and holiday time
• paid parental leave
• summer hours
• flex place/flex time options

Equal Opportunity Employer/Protected Veterans/Individuals with Disabilities

This employer is required to notify all applicants of their rights pursuant to federal employment laws.

For further information, please review the Know Your Rights notice from the Department of Labor.