What are the responsibilities and job description for the Senior Process Engineer position at Plastic Executive Recruiters?
Senior Process Engineer: Profile Extrusions
We are seeking a highly skilled Senior Process Engineer with deep subject matter expertise in Profile Extrusion. In this role, you will be the technical lead for our extrusion operations, responsible for optimizing complex production lines—from material blending and tooling setup to downstream calibration—for products such as window lineals, piping, and custom fenestration profiles.
The ideal candidate possesses a "hands-on" mastery of PVC rheology, twin-screw extrusion technology, and the precision cooling/calibration required to maintain tight dimensional tolerances.
Key Responsibilities
- Process Optimization: Design, implement, and refine extrusion processes to maximize throughput while minimizing scrap. Lead "First-Time-Right" initiatives for new profile launches.
- Tooling & Calibration: Oversee the commissioning of new dies and calibrators. Troubleshoot flow imbalances, surge issues, and dimensional instabilities in PVC profiles.
- Technical Leadership: Act as the primary technical resource for twin-screw and single-screw extrusion lines. Provide mentorship to junior engineers and lead training for line operators.
- Formulation & Material Science: Collaborate with R&D on dry-blend formulations (stabilizers, impact modifiers, fillers) to ensure processability and meet ASTM/AAMA performance standards.
- Continuous Improvement: Utilize Lean Six Sigma methodologies to identify bottlenecks and execute capital projects (CapEx) for equipment upgrades and automation.
- Quality Assurance: Establish Process Control Plans and work with Quality teams to ensure all profiles meet structural and aesthetic requirements (color, gloss, impact strength).
Required Qualifications
- Education: Bachelor’s degree in Chemical Engineering, Mechanical Engineering, Plastics Engineering, or a related technical field.
- Experience: 7 years of direct experience in Profile extrusion (specifically profiles, pipe, or fenestration).
Technical Expertise:
- Expert-level knowledge of Twin-Screw Extruders (conical and parallel).
- Deep understanding of PVC-specific processing (heat stability, shear sensitivity, and fusion rates).
- Experience with vacuum calibration tables, pullers, and inline fabrication/sawing.
- Software: Proficiency in CAD (AutoCAD/SolidWorks) and statistical analysis software (Minitab or similar).
Preferred Skills
- Experience with Co-extrusion (Capstock) and dual-durometer applications.
- Knowledge of tooling design and flow simulation software.
- Six Sigma Green or Black Belt certification.
Salary : $90,000 - $140,000