Senior Process Engineer

The Senior Process Engineer leads the design, commissioning, and operation of hazardous materials production plants, with a strong focus on chemical process engineering fundamentals and hands-on plant experience. This role develops process designs and control strategies, oversees pilot plant operations, mentors junior engineers, and supports fast-paced projects that contribute to critical national programs. The position requires frequent travel to a project site in Texas and close collaboration with a small, cross-functional engineering team based in Littleton, Colorado.

Responsibilities

• Serve as the project lead for production plant design and commissioning, guiding projects from concept through start-up.
• Travel to the project site in Texas approximately 50% of the time to support design reviews, commissioning, and on-site problem solving.
• Develop detailed engineering diagrams, including process and instrumentation diagrams (P&IDs), to define process flows and control strategies.
• Create process equipment specifications and data sheets to support procurement and installation of process equipment.
• Develop process instrumentation and control strategies in coordination with automation and controls engineers.
• Coordinate with automation and advanced process monitoring teams to integrate process control systems into batch and continuous flow operations.
• Lead and oversee pilot plant commissioning activities, including planning and executing test production runs.
• Monitor and guide pilot plant operations to validate process performance and support scale-up to full production.
• Review and oversee process deliverables prepared by junior engineers, providing mentorship, feedback, and technical guidance.
• Ensure that engineering deliverables are completed accurately and on schedule, supporting overall project timelines and milestones.
• Perform project engineering tasks such as writing technical reports, preparing documentation, and delivering technical presentations to internal and external stakeholders.
• Apply strong chemical engineering fundamentals to solve complex process problems in hazardous materials and chemical manufacturing environments.
• Handle hazardous and energetic materials with strict adherence to safety processes, procedures, and regulatory requirements.
• Support company compliance with restricted information security regulations by following established protocols and documentation practices.
• Contribute to modular plant design efforts and support both batch and continuous flow processing projects.
• Collaborate closely with a cross-functional team in a fast-paced, high-accountability environment to deliver high-quality engineering solutions.
• Demonstrate superior attention to detail in all aspects of design, documentation, and plant operations.
• Communicate effectively with team members and stakeholders through clear verbal communication and well-structured written reports.

• Proven experience in process engineering, plant design, and batch processing operations.
• Hands-on experience with hazardous material processing or manufacturing in areas such as energetic materials, explosives, pharmaceuticals, petroleum, or similar industries.
• Strong chemical engineering fundamentals combined with practical, hands-on plant experience.
• Demonstrated ability to lead the design and commissioning of hazardous materials production plants.
• Proficiency in developing P&IDs, equipment specifications, and process control strategies.
• Experience integrating automation and advanced process monitoring systems into chemical processes.
• Experience with pilot plant operations, including commissioning and execution of test production runs.
• Ability to mentor and review the technical work of junior engineers, providing constructive feedback and guidance.
• Proficiency with Aspen Plus for process modeling and design.
• Experience with modular design and both batch and continuous flow processing.
• Strong problem-solving skills with the ability to work effectively in a team environment on fast-paced projects.
• Strong verbal and written communication skills for technical presentations and documentation.
• Superior attention to detail in design, analysis, and documentation.
• Ability to handle hazardous materials safely and consistently follow safety process requirements.
• Physical ability to sit for extended periods, lift up to 50 pounds, and bend, sit, stand, and lift as needed to perform job duties.
• Ability to work effectively with a computer monitor and perform tasks requiring near and far vision.

• Background in chemical engineering or a closely related engineering discipline.
• Experience working with energetics or explosives in a controlled manufacturing or pilot plant environment.
• Experience supporting projects related to government, defense, or energy sectors.
• Comfort working in a high-accountability environment with hazardous materials and strict safety and security requirements.
• Ability to prepare clear, concise technical reports and deliver compelling technical presentations.
• Demonstrated ability to manage multiple tasks and priorities while maintaining high-quality work.

This role is based with an onsite engineering team in Littleton, Colorado, working within a small, collaborative, and cross-functional group. The work environment combines office-based design and analysis with hands-on commissioning and pilot plant activities. The position involves frequent travel, with approximately 50% of the time spent at a project site in Texas to support on-site design, commissioning, and operations. The team operates in a fast-paced, high-accountability setting, working directly with hazardous materials, energetic materials, and advanced process equipment. Engineers use tools such as Aspen Plus and work with modular plant designs, batch and continuous flow processing, and integrated automation and advanced process monitoring systems. The organization offers flexible schedules such as 9/80 or 4/10 workweeks, extended flex time, paid training hours each year, and a comprehensive benefits package that includes substantial health insurance coverage and a competitive retirement plan match. The culture emphasizes safety, technical excellence, collaboration, and meaningful work that supports critical national programs.

Job Type & Location

This is a Permanent position based out of Littleton, CO.

The pay range for this position is $95000.00 - $150000.00/yr.

401k Match100% health insurance paid + premium for dependents Extended Flex TimePotential Hybrid flexibility 9/80 or 4/10 schedule

This is a fully onsite position in Littleton,CO.

This position is anticipated to close on Apr 24, 2026.

Diversity, Equity & Inclusion

At Actalent, diversity and inclusion are a bridge towards the equity and success of our people. DE&I is embedded into our culture through:

• Hiring diverse talent
• Maintaining an inclusive environment through persistent self-reflection
• Building a culture of care, engagement, and recognition with clear outcomes
• Ensuring growth opportunities for our people

Actalent is an equal opportunity employer.

About Actalent

Actalent is a global leader in engineering and sciences services. For more than 40 years, we’ve helped visionary companies advance their goals. Headquartered in the United States, our teams span 150 offices across North America, EMEA, and APAC—with four delivery centers in India led by 1,000+ extraordinary employees who connect their passion with purpose every day.

Our Bangalore, Hyderabad, Pune, and Chennai delivery centers are hubs of engineering expertise, with core capabilities in mechanical and electrical engineering, systems and software, and manufacturing engineering. Our teams deliver work across multiple industries including transportation, consumer and industrial products, and life sciences. We serve more than 4,500 clients, including many Fortune 500 brands. Learn more about how we can work together at actalentservices.com.