Polypropylene Extrusion Process Engineer

Job Description

Company: SeaCa Plastic Packaging, LLC

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Salary: $87,500–$100,000 annually, depending on experience

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Department: Operations / Manufacturing Engineering

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Reports To: Production Manager

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Role Description The Polypropylene Extrusion Process Engineer is a full-time, on-site role located in the Surprise, AZ. This position will focus on optimizing the production of hollow form polypropylene (PP) sheets and carton products. The ideal candidate will bring hands-on extrusion experience, strong troubleshooting abilities, and a passion for improving manufacturing efficiency, product quality, and equipment performance.

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Process Engineering & Production Optimization

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• Monitor and optimize polypropylene extrusion processes to improve productivity, quality, and efficiency.
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• Troubleshoot extrusion equipment and resolve production-related issues.
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• Develop and improve processing parameters, including temperature profiles, screw speeds, melt pressures, line speeds, and cooling conditions.
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• Analyze production data to identify opportunities to increase throughput, reduce scrap, and minimize downtime.
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• Conduct root cause analysis and implement corrective actions to address recurring manufacturing issues.
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• Lead continuous improvement projects using Lean Manufacturing, Six Sigma, or similar methodologies.
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Quality & Product Development

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• Ensure products meet specifications for thickness, weight, flute geometry, stiffness, and dimensional stability.
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• Partner with Quality Assurance to address quality concerns and customer complaints.
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• Evaluate raw materials, additives, resin formulations, and recycled content.
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• Support new product development, process validation, customer trials, and production scale-up.
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Qualifications

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• Strong foundation in Chemical Engineering and Process Engineering, with experience in polymer or plastics processing, preferably polypropylene extrusion.
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• Proficiency in Process Design, including the development and optimization of extrusion lines, equipment layouts, and process flows.
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• Experience with Process Control, including setting and maintaining operating parameters, implementing control strategies, and working with instrumentation and automation systems.
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• Advanced Analytical Skills to interpret process data, perform root-cause analysis, and drive data-based improvements in quality, throughput, and efficiency.
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• Bachelor’s degree in Chemical Engineering, Mechanical Engineering, or a related field; advanced degree or relevant certifications in plastics or extrusion engineering are a plus.
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• Knowledge of safety, environmental, and food-contact packaging regulations and standards; experience in a manufacturing environment is preferred.
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• Ability to work collaboratively on-site with cross-functional teams, communicate technical information clearly, and manage multiple projects in a fast-paced setting.
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• Commitment to sustainability, continuous improvement, and maintaining a safe work environment.
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