Process Engineer - Plastics Extrusion

About the Role

LV Search Partners is helping a leading plastics manufacturer hire a Plastics Extrusion Process Engineer to optimize and maintain multi-layer extrusion operations for high-performance thermoplastics. This role is ideal for an engineer who enjoys hands-on problem solving, process optimization, and collaborating with cross-functional teams to achieve quality, efficiency, and innovation on the production floor.

What You’ll Do

• Design and optimize extrusion parameters for 5-layer blends of HDPE, LDPE, LLDPE, Admer (adhesive), and EVOH (barrier) materials.
• Adjust temperature profiles, screw configurations, and die designs to meet resin-specific flow and cooling characteristics.
• Evaluate resin properties such as melt index, density, and additives for process compatibility and end-use requirements.
• Lead tooling trials and implement modifications to improve dimensional accuracy, stability, and surface finish.
• Troubleshoot issues such as melt fracture, die drool, gel formation, and gauge variation using diagnostic tools like pressure sensors, IR cameras, and rheometers.
• Ensure products meet stringent quality criteria including tensile strength, puncture resistance, and elongation performance.
• Document blend ratios, process settings, and performance data for traceability and continuous improvement.
• Support audits and validations for cosmetic-grade polyethylene applications.
• Lead continuous improvement initiatives focused on efficiency, cost reduction, and sustainability.

What You Bring

• In-depth knowledge of HDPE, LDPE, and LLDPE resin properties and behavior under extrusion.
• Experience with multi-layer extrusion systems and tooling, including 5-layer die and mold configurations.
• Strong analytical and problem-solving skills for process optimization and root cause analysis.
• Proficiency with SPC tools, data logging, and process monitoring systems (ISO 9001 experience preferred).
• Hands-on mechanical aptitude with extruders, gravimetric feeders, and tooling maintenance.
• Excellent communication and documentation skills for cross-functional collaboration and reporting.
• Proven ability to train operators and technicians on process improvements and safety protocols.
• Willingness to work flexible hours as needed to support production operations.