What are the responsibilities and job description for the Senior Extrusion Engineering Leader position at Full Circle Recruiting?
Position Overview
We are seeking a highly experienced Senior Extrusion Engineering Leader to drive operational excellence across twin screw profile extrusion operations. This role is ideal for a hands-on technical expert with deep expertise in foamed PVC processing and profile manufacturing, particularly within fencing or structural profile applications.
The ideal candidate will bring a minimum of 20 years of total plastics extrusion experience, with significant time spent leading twin screw extrusion lines, optimizing foamed PVC processes, and overseeing tooling design and line performance.
This is a high-impact leadership role responsible for process optimization, tooling strategy, production efficiency, and continuous improvement across extrusion operations.
Candidates must be located within a reasonable commuting distance to W Highway 30, Ellendale, MN. Relocation assistance is not available for this position.
Key Responsibilities
- Lead and optimize twin screw extrusion operations, specifically in rigid and foamed PVC applications
- Oversee profile extrusion manufacturing, including fencing and structural profiles
- Drive line balancing initiatives to improve throughput and reduce scrap
- Serve as a setup expert for new and existing extrusion lines, reducing startup time and stabilizing production
- Design, evaluate, and optimize extrusion tooling, including dies and downstream calibration systems
- Monitor and adjust foaming parameters to control density, cell structure, and product consistency
- Improve process stability, reduce downtime, and enhance overall equipment effectiveness (OEE)
- Support commissioning of new extrusion equipment and upgrades
- Partner with maintenance and production teams to troubleshoot mechanical and process-related issues
- Develop SOPs and best practices for twin screw extrusion and foamed profile production
- Lead continuous improvement initiatives to reduce scrap and increase efficiency
Required Experience
- Minimum 20 years of total plastics extrusion experience
- Extensive hands-on experience with twin screw extrusion systems (counter-rotating or co-rotating)
- Demonstrated experience in foamed PVC processing
- Strong background in profile extrusion manufacturing, preferably fencing or similar structural profiles
- Proven expertise in extrusion tooling design and optimization
- Experience balancing production lines to increase throughput and reduce bottlenecks
- Track record of measurable operational improvements (scrap reduction, startup time improvement, downtime reduction)
- Deep understanding of foam structure control, density management, and process stabilization
- Experience with extrusion line setup, commissioning, and troubleshooting
Preferred Qualifications
- Mechanical or Plastics Engineering background (degree preferred but not required with strong hands-on experience)
- Experience leading extrusion teams in a manufacturing environment
- Strong understanding of downstream equipment (calibrators, vacuum sizing tanks, pullers, cutters)
- Lean Manufacturing and Continuous Improvement experience
- Ability to work cross-functionally with production, maintenance, and engineering teams
What We’re Looking For
We are seeking a seasoned extrusion professional who is:
- Highly hands-on and technically strong
- Comfortable working directly on the production floor
- Skilled in solving complex foaming and tooling challenges
- Capable of stabilizing and optimizing high-output profile lines
- Focused on efficiency, quality, and output consistency
This is not an entry-level or developmental role — we are seeking a veteran extrusion expert who can immediately add value and elevate twin screw and foamed profile operations.