This role pays less than
53%
of similar roles. Most pay
$139,375–$178,062
— the shaded band above.
At the midpoint, this role pays about
$151k
versus about
$159k
for comparable roles.
Based on 240 similar postings.
Employer
About MSD
MSD (Merck Sharp & Dohme) is the international name for Merck & Co., a major U.S.-based pharmaceutical company.
MSD currently has
47 open roles
on FindRole.
Listed pay typically runs
$117,000–$184,200
across 47 roles with salary data.
Senior Process Engineer, Technical Operations – Small Molecule Drug Product (Spray Drying) joins the technical operations team to provide leadership and process ownership for drug product intermediate manufacturing. This role focuses on spray drying, particle engineering, solid-state control, and downstream processing into dosage forms like blending and compaction. The successful candidate will manage equipment selection, commissioning, qualification, and startup while leading technology transfers from R&D to commercial manufacturing. Day-to-day responsibilities include interpreting material data such as PSD and morphology, troubleshooting powder handling challenges like sticking or fouling, and implementing continuous improvements using Root Cause Analysis and Design of Experiments. The role requires expertise in cGMP, process validation, and scale-up principles for spray dryers. Candidates must possess a degree in Chemical Engineering or Pharmaceutical Sciences and experience in manufacturing processes to ensure high standards of data integrity and operational excellence.
What does a Process Engineer earn?
Median $150600 from 37 postings across 7 companies.
Provide technical leadership for drug product intermediate manufacturing processes including spray drying, particle engineering, and powder handling.
Act as the subject matter expert for spray drying equipment, selection, and associated unit operations.
Lead process scale-up, technology transfer from R&D sites, and validation activities such as PPQ.
Interpret material data like PSD and morphology to drive data-driven decisions and performance improvements.
Provide advanced troubleshooting for manufacturing challenges including yield losses, sticking, fouling, and powder flowability.
Drive continuous improvement initiatives to enhance particle consistency, process robustness, and production throughput.
Ensure all manufacturing activities comply with cGMP, safety standards, and environmental regulations.
Manage technical documentation including batch records, process descriptions, and control strategies for regulatory audits.
What we're looking for
Degree in Chemical Engineering, Pharmaceutics, Pharmaceutical Sciences, or a related discipline.
Typically 5+ years of experience in drug product intermediate, spray drying, or pharmaceutical process development/manufacturing (PhD may offset experience).
Strong experience in spray drying and particle engineering processes.
Understanding of scale-up principles for spray dryers from lab to commercial scale.
Experience in solid-state characterization and material science including PSD, morphology, and solid-state control.
Demonstrated involvement in technology transfer, process validation (PPQ), and commercial manufacturing support.
Working knowledge of cGMP and regulatory expectations.
Experience with downstream processing into drug product such as blending or compaction is preferred.
cGMP
Oral Solid Dosage
Technology Transfer
Process Validation
PPQ
Root Cause Analysis
DOE
Chemical Engineering
Pharmaceutics
Blending
Granulation
Roller Compaction
Tablet Compression
Film Coating
Process Optimization
Commissioning and Qualification (CQV)
Master Batch Records
Continuous Manufacturing
cGMP
Chemical Engineering
API Manufacturing
Process Optimization
Technology Transfer
Root Cause Analysis (RCA)
Manufacturing Process Validation
Chemical Synthesis
Purification
Crystallization
Drying Operations
Scale-up
Data Integrity
Change Control
Deviation Management
Commissioning
Qualification
Chemical Engineering
Chemistry
cGMP
API Manufacturing
Process Development
Technology Transfer
Commissioning
Qualification
Validation
Root Cause Analysis
CAPA
Data Analysis
Lean Manufacturing
Project Management
Technical Writing
Scale-up
Process Optimization
Equipment Troubleshooting
cGMP
API Manufacturing
Process Engineering
Technology Transfer
Commissioning
Qualification
Validation
PPQ
Root Cause Analysis
CAPA
Data Analysis
Chemical Engineering
Scale-up
Manufacturing Operations
Process Optimization
safety, and environmental standards
cGMP
DeltaV
Process Engineering
Scale-up
Technology Transfer
Validation
Root Cause Analysis
CAPA
OOS
Data Integrity
Chemical Engineering
Pharmaceutics
Pharmaceutical Sciences
Lean Manufacturing
Capital Project Management
Commissioning
Qualification
Verification
Drug Product Manufacturing
GMP
Technology Transfer
Process Engineering
Scale-up
Validation
Chemical Process Development
CAPA
Root Cause Analysis
Data Integrity
ICH Guidelines
Quality Systems
Risk Management
CPV Analytics
Manufacturing Scale-up
Small Molecule Manufacturing
Audit Readiness