Process Engineer

AmeriStaff Employment & Staffing Solutions is currently seeking a Process Engineering Manager for a direct hire opportunity with a manufacturing client in Ridgeway, VA. This leadership role is responsible for applied engineering and process development for Nylon yarn and textile systems, driving innovation, product optimization, and technical problem-solving across yarn, fabric, and garment applications. The ideal candidate will have a strong background in textile engineering, chemical engineering, or polymer processing, with experience supporting customer-driven product development and continuous process improvement.

Benefits of the Process Engineering Manager:

• Direct Hire Opportunity
• Competitive Salary (Based on Experience & Qualifications)
• Comprehensive Benefits Package Available
• Opportunity to lead innovative textile and process engineering initiatives

Responsibilities of the Process Engineering Manager:

• Lead engineering development, optimization, and validation of Nylon yarn-to-fabric systems using circular knitting, warp knitting, and weaving platforms.
• Partner with new and existing customers to develop optimized yarn specifications tailored to specific fabric construction, performance requirements, and end-use applications.
• Define, evaluate, and optimize yarn parameters including denier, filament count, cross-section, finishes, and interlace characteristics to meet targeted mechanical and functional performance standards.
• Conduct root-cause analysis and troubleshoot technical issues related to yarn processing, fabric performance, dyeing, finishing, and garment functionality.
• Collaborate closely with R&D, manufacturing, and production teams to implement process-driven innovation and continuous improvement initiatives.
• Lead and oversee lab trials, pilot testing, mill trials, and benchmarking studies against competitive materials and technologies.
• Support the development, implementation, and validation of sustainable Nylon and alternative material solutions.
• Analyze and improve polymer processing, spinning performance, extrusion parameters, and thermal processing to maximize product quality and manufacturing efficiency.
• Monitor and optimize chemical formulations, textile finishes, additives, and process chemistry to improve product performance and consistency.
• Evaluate textile manufacturing variables such as tension, shrinkage, dye uptake, moisture management, durability, tensile strength, and fabric performance characteristics.
• Develop and maintain process control strategies, quality standards, and performance metrics to ensure consistent manufacturing output.
• Drive continuous improvement projects focused on waste reduction, efficiency, quality enhancement, and cost savings.
• Provide technical leadership and engineering support for customer-driven product development and commercialization efforts.
• Develop technical documentation, SOPs, engineering procedures, process guidelines, and training materials.
• Mentor and provide technical guidance to engineering, technical, and production teams as needed.
• Ensure compliance with safety, quality, and environmental standards within engineering and manufacturing operations.
• Perform additional duties as assigned by management.

Requirements of the Process Engineering Manager:

• Master’s degree in Textiles required.
• Degree concentration in Textile Engineering, Chemical Engineering, Polymer Science, Materials Science, or a related technical field strongly preferred.
• Strong experience in textile manufacturing, Nylon yarn systems, polymer processing, or engineered textile products required.
• Experience with circular knitting, warp knitting, weaving, yarn development, or textile performance testing preferred.
• Knowledge of polymer chemistry, extrusion/spinning processes, textile finishing, and process optimization strongly preferred.
• Experience with root-cause analysis, process validation, and continuous improvement methodologies.
• Strong analytical, troubleshooting, and problem-solving skills in a manufacturing environment.
• Ability to interpret technical data and translate engineering findings into actionable process improvements.
• Excellent communication and customer-facing skills with the ability to collaborate across departments and with external partners.
• Experience leading technical projects, product development, or engineering initiatives preferred.
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