Plastics Process Engineer

JOB DESCRIPTION

Summary/Objective

The Plastics Extrusion Process Engineer is responsible for optimizing and maintaining extrusion manufacturing processes to ensure consistent product quality, efficiency, and safety. This role involves designing, implementing, and improving extrusion techniques for thermoplastics, troubleshooting equipment and material issues, and collaborating with cross-functional teams to support production goals. The engineer will apply technical expertise in polymer behavior, tooling design, and process control to drive continuous improvement and innovation in extrusion operations. Familiarity with 5-layer die and mold systems is advantageous for maintaining dimensional accuracy and layer integrity.

Essential Functions

Extrusion Process Development

• Design and optimize extrusion parameters for 5 layer blends of high-density (HDPE), low-density (LDPE), linear low-density polyethylene (LLDPE) materials, Admer (adhesive) and EVOH (barrier).
• Adjust temperature profiles, screw configurations, and die designs to accommodate resin-specific flow and cooling characteristics.

Material Handling and Compatibility

• Evaluate resin properties such as melt index, density, and additives to ensure compatibility with extrusion equipment and end-use requirements.
• Collaborate with suppliers to qualify new grades of HDPE, LDPE, and LLDPE for specific applications (e.g., tubing, profiles).

Tooling and Equipment Support

• Lead tooling trials and implement modifications to improve dimensional stability and surface finish.

Process Troubleshooting

• Resolve issues such as melt fracture, die drool, gel formation, and gauge variation common in polyethylene extrusion.
• Use diagnostic tools (e.g., pressure sensors, IR cameras, rheometers) to identify root causes and implement corrective actions.

Quality Assurance and Compliance

• Ensure extruded products meet performance criteria such as tensile strength, puncture resistance, and elongation, tailored to blend composition.
• Support audits and validations for cosmetics grade polyethylene applications.
• Confirmation of dimensional accuracy in wall and layer thickness and ensuring all manufactured parts meet both internal R4 criteria and externally defined R4 customer specifications.

Documentation and Technical Reporting

• Maintain detailed records of blend ratios, process settings, and performance metrics for traceability and continuous improvement.
• Generate technical reports on blend trials, process validations, and material performance.

Continuous Improvement and Innovation

• Lead initiatives to optimize blend usage for cost, performance, and sustainability.
• Explore advanced blending techniques, co-extrusion strategies, and recycled content integration.

Job Skills & Requirements

· Technical Expertise - In-depth knowledge of HDPE, LDPE, and LLDPE resin properties, including melt index, density, and thermal behavior; Experience with multi-layer extrusion.

· Process and Quality Control - Skilled in using SPC tools, data logging systems, and process monitoring software; Ability to conduct root cause analysis and implement corrective actions for process deviations. ISO 9001 preferred experience.

· Analytical and Problem-Solving - Strong analytical skills for interpreting process trends, and material performance; Ability to optimize blend ratios for cost, performance, and processability.

· Mechanical Aptitude- Knowledge of mold and machine tooling design and maintenance for polyethylene blends; Hands-on experience with extruders and gravimetric feeders.

· Attention to Detail- Ensures product quality and detects equipment issues early.

· Teamwork - Works effectively with technicians, supervisors, and other team members. Ability and willingness to train others.

· Documentation and Communication - Proficient in creating and maintaining SOPs, technical reports, and process documentation; Effective communicator across engineering, production, quality, and supplier teams; Capable of training operators and technicians on blend-specific extrusion practices. Experience managing change orders with strict compliance to customer-approved specifications.

· Basic Troubleshooting Skills - Identifies and reports machine malfunctions; assists technicians with repairs.

· Time Management - Manages tasks efficiently to meet production deadlines.

· Safety – Observes good safety practices.

· Willingness to Work Flexible Hours - May include early mornings, evenings, weekends, or overtime as needed.

Work Environment

This position operates in a manufacturing environment. The use of standard office equipment may be required.

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job.

While performing the duties of this job, the employee is occasionally required to stand; walk; sit; use hands to finger, handle, or feel objects, tools or controls; reach with hands and arms; climb stairs; talk or hear. The employee must occasionally lift or move office products and supplies, up to 50 pounds.

Travel

Travel is not required.

Supervisory Responsibilities