Senior Process Engineer, Technical Operations β Small Molecule Drug Product (Spray Drying)
Merck
August 26, 2026
Full-time
Remote friendly (Elkton, VA)
Worldwide
Operations
Role: Senior Process Engineer leading technical operations for small molecule drug product, focusing on spray drying processes. Responsibilities include providing process ownership, process development, scale-up, technology transfer, validation, and optimizing manufacturing efficiency for spray dried intermediates and drug products. The candidate will support facility design, commissioning, qualification, and commercial production, acting as SME for spray drying and related unit operations. They will lead or coordinate process validation activities, troubleshoot technical issues, and drive continuous improvement initiatives aligned with cGMP standards. Collaboration involves cross-functional teams across Manufacturing, R&D, Quality, and Engineering, supporting technology transfer and process optimization. Qualifications: Degree in Chemical Engineering, Pharmaceutics, or related field; 5+ yearsβ experience in pharmaceutical process development or manufacturing, with expertise in spray drying, particle engineering, and solid-state characterization. Experience in process validation (PPQ), technology transfer, and commercial manufacturing is required. Knowledge of cGMP, regulatory compliance, and downstream processing is preferred. Skills include data analysis, problem-solving, technical leadership, and effective communication. The position involves 10% travel, with a hybrid or onsite work setup. This role emphasizes operational excellence, process robustness, and scalable manufacturing of small molecule products, contributing to site growth and product quality.